4.0 Operating Instructions

FAS4 User Manual
FAS4 User Manual
Table of Contents
1. First Steps ....................................................................................................................................... 7
1.1. Introduction........................................................................................................................................7
1.2. Safety information..............................................................................................................................8
1.3. Connecting to the maker ....................................................................................................................8
1.4. Switching on the FAS4 ........................................................................................................................9
1.5. Switching off the FAS4........................................................................................................................9
1.6. UPS operation...................................................................................................................................10
2. General Information On Visualization ............................................................................................ 11
2.1. Main menu .......................................................................................................................................11
2.2. User administration ..........................................................................................................................11
2.2.1. User levels ................................................................................................................................12
2.2.2. Changing the user .....................................................................................................................12
2.2.3. Changing your own user log-on................................................................................................12
2.3. Creating a screenshot .......................................................................................................................13
2.4. Online help .......................................................................................................................................13
2.5. Switching languages .........................................................................................................................13
2.6. Functional structure of the display ..................................................................................................13
2.6.1. The headline .............................................................................................................................14
2.6.2. The toolbar ...............................................................................................................................14
2.6.3. The main screen .......................................................................................................................15
2.7. Indicators ..........................................................................................................................................15
2.7.1. Status indicators on the headline .............................................................................................15
2.7.2. Traffic light indicators in the “Produktion” window ................................................................15
2.7.3. Status indicators of the process engineering ...........................................................................15
2.7.4. Status indicators of the heating system ...................................................................................16
3. The process pictures of the FAS4 ................................................................................................... 17
3.1. Process overview ..............................................................................................................................17
3.2. Production overview ........................................................................................................................18
3.3. Process..............................................................................................................................................18
3.4. Quality recording ..............................................................................................................................20
3.5. Trending ...........................................................................................................................................20
3.6. Maintenance menu ..........................................................................................................................21
3.6.1. Filters and hoses .......................................................................................................................21
3.7. Statistics ...........................................................................................................................................22
3.8. Alarms...............................................................................................................................................22
1 - First Steps 3
3.9. Alarm history ................................................................................................................................... 24
4. Set-up and Parameterization ........................................................................................................ 25
4.1. Machine parameters ....................................................................................................................... 25
4.1.1. External 1 ................................................................................................................................. 25
4.1.2. Process 1 .................................................................................................................................. 26
4.1.3. Flavor change during operation............................................................................................... 28
4.1.4. Buffer tank area ....................................................................................................................... 28
4.1.5. Process 2, External 2 ................................................................................................................ 29
4.2. Control circuits................................................................................................................................. 29
4.2.1. Controller settings ................................................................................................................... 30
4.2.2. Controller overview ................................................................................................................. 32
4.3. Alarm limits ...................................................................................................................................... 33
4.3.1. External 1 ................................................................................................................................. 34
4.3.2. Process 1 .................................................................................................................................. 35
4.3.3. Buffer tank area ....................................................................................................................... 37
4.3.4. Process 2, External 2 ................................................................................................................ 38
4.4. Calibration ....................................................................................................................................... 38
5. Producing Using the FAS4 (Production Mode) ............................................................................... 41
5.1. Introduction ..................................................................................................................................... 41
5.2. Preparation ...................................................................................................................................... 41
5.3. Entering the production parameters and starting production........................................................ 41
5.3.1. Cold/warm operation and key switches .................................................................................. 42
5.3.2. Entering the production parameters (cigarette maker) .......................................................... 43
5.3.3. Entering the production parameters (filter maker)................................................................. 43
5.3.4. Entering the production parameters (winding or paper machine) ......................................... 44
5.3.5. FAS4 production preparation .................................................................................................. 45
5.4. Production ....................................................................................................................................... 46
5.4.1. Switching on the agitator ........................................................................................................ 46
5.4.2. Standby and auto standby ....................................................................................................... 47
5.4.3. Setting the air pressure for the two-component nozzle ......................................................... 47
5.4.4. Retiring flavour ........................................................................................................................ 48
5.5. Ending production ........................................................................................................................... 48
6. Operating modes .......................................................................................................................... 49
6.1. Production mode ............................................................................................................................. 49
6.2. Manual operation ............................................................................................................................ 49
6.3. Semi operation or semi-automatic .................................................................................................. 50
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FAS4 User Manual
6.3.1. Cleaning circulation ..................................................................................................................50
6.3.2. Spray cleaner ............................................................................................................................50
6.3.3. Displace cleaner........................................................................................................................51
6.3.4. Flavour circulation ....................................................................................................................51
6.3.5. Spray flavour.............................................................................................................................51
6.3.6. Displace flavour ........................................................................................................................51
6.4. Automatic .........................................................................................................................................52
7. Cleaning ....................................................................................................................................... 53
7.1.1. Manual Cleaning .......................................................................................................................54
7.1.2. Cleaning the external tank .......................................................................................................55
7.1.3. Completely empty the tank ......................................................................................................57
7.1.4. Clean the wires .........................................................................................................................60
7.1.5. Cleaning the station..................................................................................................................61
7.1.6. Cleaning of the filter .................................................................................................................62
8. The External Flavour Tank (Optional) ............................................................................................. 63
8.1. Construction .....................................................................................................................................63
8.2. The control panel .............................................................................................................................63
8.3. Filling ................................................................................................................................................64
8.4. Melting and preparing the flavour ...................................................................................................64
8.5. Coupling to the FAS4 ........................................................................................................................65
8.6. The agitator ......................................................................................................................................66
8.7. Cleaning ............................................................................................................................................66
9. The Additional Screen (Optional) ................................................................................................... 68
9.1. Introduction......................................................................................................................................68
9.2. Connection between the monitor and the FAS4..............................................................................69
9.3. Using the monitor on several FAS4 units .........................................................................................69
9.4. Troubleshooting ...............................................................................................................................69
10. FAS4 diagnosis view (optional) ...................................................................................................... 70
10.1. Main view .....................................................................................................................................70
10.2. Configuration of interface terminals ............................................................................................71
10.3. Schematics ....................................................................................................................................72
10.4. Examples.......................................................................................................................................72
10.4.1. Air supply failure.......................................................................................................................72
10.4.2. Failure of analogue input .........................................................................................................73
11. Recording production data (optional) ............................................................................................ 74
12. Glossary........................................................................................................................................ 77
1 - First Steps 5
13. Alarm messages ........................................................................................................................... 79
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FAS4 User Manual
1. First Steps
1.1. Introduction
The Flavor Application System (FAS$), manufactured by Köhl, is a mobile unit for
applying flavour in a homogeneous way:
• into the suction-rod conveyor of the cigarette maker
• into the transportation beam of any type of filter cigarette maker
• onto paper or similar material
Depending on the type of FAS$ model you are working with, you can apply different
flavours or additives in various ways. The main differences between the models are
whether they are designed for one chain lane or two and whether they have an
integrated heating system for natural menthol or not.
You can see which model you are working with by means of the FAS$ type code and the
table below. The type code may, for example, look like this:
FAS4 UNI TWIN 240 Z 0
Using the table, you can now see which functions and options are implemented in your
equipment:
Type code Variants Description
FAS4 FAS4 Current version of the FAS system
FAS5 Further development of the FAS4; not yet available
UNI COLD For “cold” flavours only
UNI For “cold” and “warm” flavours
TWIN CLASSIC For single-rod makers only
TWIN Single- and double-rod makers
240 120 Maximum application of 120 g/min
240 Maximum application of 240 g/min
480 Maximum application of 480 g/min
Z F Filter application
Z Cigarette application
FZ Filter and cigarette application
WBF Water-Based Flavour
S Special application
0 0 No special construction
1 Emergency OFF & 90° connecting plug
2 Container for tiny amounts
3 Other customization
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1 - First Steps 7
TW 4 COLD
Type code Variants Description

TW 4 Current version of the FAS system
5 Further development of the FAS4; not yet available
COLD COLD For “cold” flavours only
UNI Für „kalte“ und „warme“ Flavor
PM Other Customization
PM+ Other Customization
WBF Water Based Flavor
The FAS4 denotes the main unit, which function it is to assign the flavor on various types
of media.
In the main unit you can find every necessary control components as well as a container
system for this purpose. The container system located in the FAS4 has only a limited
capacity. To expand this volume, an external tank can be used in conjunction with the
FAS4. It’s task is it to refill the internal tank when needed.
In order to produce the same physical state of the flavor, there is the possibility to let
the external tank operate independently. In this process, the flavor can be prepared
elsewhere and proceed to the FAS4 when needed, by docking to the FAS4 system.
The external tank does only operate as an additional unit and does not affect the
essential function (order of flavor) of the FAS4.
A number of the points in the manual refer to different FAS4 options or variants. At the
appropriate location, we will point this out, which allows you to skip unnecessary
information.
Some important terms for handling the FAS4 are explained in the glossary (Chapter 12).
1.2. Safety information
Only trained specialist staff are allowed to operate the FAS4. Observe the
safety information in the main documentation and ensure that the system
is used as intended.
1.3. Connecting to the maker

The FAS4 is supplied with compressed air and electricity via the connection line on the
system and the connection socket on the maker that is specially attached for the FAS4 to
use. Refer to Chapter 6.2 of the main documentation for the pin assignment of the plug
and for an overview of the signals that are exchanged between the maker and the FAS4.
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FAS4 User Manual
Since the FAS4 is looped into the Maker's safety circuit, it is only possible to start the
Maker when the FAS4 is ready for production. If you want to run the Maker without
an FAS4 being connected, please plug in the dummy plug to the socket on the Maker.
You must not connect or disconnect the Maker when it is energized or under
load. Ensure that the FAS4's main switch is switched off.
Ensure that the compressed air is only connected and disconnected with the
system depressurized.
1.4. Switching on the FAS4

After making the connection to the Maker, check whether all the fuses and the RCCB are
activated. If this is the case, you can switch on the system at the main switch. When
switching on, ensure that the control cabinet door is closed. The system now starts up
and after the IPC has booted or visualization has started, the system is ready to operate.
1.5. Switching off the FAS4

Before switching off the system, you must first end the current production run (see
Chapter 5.5). After this, you can shut down the FAS4 using the “Shut down” item in the
main menu. Once the IPC has automatically switched off, you can de-energize the
system at the main switch.
hat, können Sie die Anlage über den Hauptschalter spannungslos schalten.
Danger of explosion caused by leakage
WARNING Every hose and every connection suffers from wear.

If you recognize any damages during the daily use of FAS4,
retention the machine and safe it against reconnection.
A service technician has to be informed immediately.
Always carry out orderly shut down of the IPC before switching off the
system. Otherwise, data can be lost and the hardware could be damaged.
If you click on the “Shut down” pushbutton during an ongoing production run, the
system issues the following message:
If it is necessary to shut down the system immediately, click on “Yes” to confirm the
prompt. Otherwise, end the production run as described in Chapter 5.5.
1 - First Steps 9
1.6. UPS operation
The FAS4 has an integrated UPS that maintains operation of the Industrial PC for
a specific amount of time in the event of a power failure. The PC continues to operate
until the battery charge level falls below 20%. After this, the system automatically closes
all the applications and shuts down the PC.
If there is an interruption to the power supply, the system informs you with the
following message:
If you want to shut down the system immediately, you can click on the “IPC shut down”
pushbutton.
If the power supply is restored before the charge level falls below 20%, the system issues
a message to this effect and you can restart the production run.
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FAS4 User Manual
2. General Information On Visualization
2.1. Main menu

After you start the FAS4, the system displays the main menu:
The elements of the main menu are as follows:

1. The number of the FAS4. If you have to contact Köhl Support, make sure you have
this number to hand.
2. The operating elements of the main menu. Clicking on these pushbuttons calls the
individual process pictures. The pushbuttons that are activated for the logged-in
user are labelled in white type.
3. Here, the system displays the current date and time. Using the camera icon, you can
create a screenshot of the current process picture (see Chapter 2.3).
4. Clicking on one of the flags switches the language of the FAS4 to that of the
respective country.
5. Output of the version numbers of the controller (PLC) and visualization (Visu). You
should keep these number handy too for when you get in touch with Support.
2.2. User administration

To protect important settings and to provide a better overview, the visualization system
of the FAS4 has different user levels. The main difference between them is that certain
parameters and windows are locked or hidden for lower-level users. The users for the
different levels are defined at the factory; however, trained personnel are able
to change the levels themselves.
2 - General Information On Visualization 11

2.2.1. User levels
The following user levels are implemented in the FAS4:
User User name Password Authorization
Operator operator operator Starting and ending the
production run
Service customer servicec servicec Maintenance functions,
basic parameters
Extended service servicem servicem Maintenance functions,
enhanced parameters,
erweiterte Parameter,
restoring parameters
Administrator XXX XXX Full access
2.2.2. Changing the user

After starting up the FAS4, user “Operator” is logged-on by default. This user has
all the authorizations to be able to carry out production with the FAS4. The
machine parameters, controller settings and different maintenance functions are
disabled for them. To log on another user, e.g. to change parameters or to carry
out through-flow calibration, please click on “logon” in the main menu. The system
then displays a dialog box in which you can use the screen keyboard to enter the
user name and the corresponding password:
If the user is not known or the password is wrong, the system informs you by
issuing a message to this effect.
To log off the current user, you just need to click on the “logon” pushbutton. After
doing this, you return to the “Operator” default user level.
2.2.3. Changing your own user log-on

Using the “user management” pushbutton in the main menu, you can change your
own user name and password.
If you change your user data, make a note of it in a safe place. If you
forget your login information, a Köhl staff member must reset the user
data.
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FAS4 User Manual
2.3. Creating a screenshot
To document at different settings, process pictures, diagrams or error messages, you can
use the camera icon to create a screenshot. Generally, this icon is located at the top
right of the screen or at the top left in the case of an error message and it is enabled for
all users.
To save the screenshot, first plug in a suitable USB stick in the USB socket on the front of
the FAS4 PC and wait for a moment until the FAS4 detects the stick. Then, click on one of
the camera icons to save the screenshot to the stick.
2.4. Online help

The most important technical documents are saved on the FAS4 as PDF files; you can call
them using the “info” pushbutton in the main menu. In the online help, you can switch
between categories on the left in the tree structure. On the right, there are the
submenus and the corresponding data sheets.
From a higher user level onwards, the system will prompt you when you click on the
“info” pushbutton whether you want to display the help or export it. If you connected
a USB stick before, you can now export the help and view or print it on another
computer.
2.5. Switching languages

By default, the English and German languages are installed on the FAS4. In addition,
customers can purchase another language. To switch languages, you just need to click
on the corresponding flag. After this, the system displays the texts in the windows in the
desired language.
2.6. Functional structure of the display

To make it easier to get around the system and to operate it, all the windows are
structured on the same principle:

2.6.1. The headline
The (red) headline shows the most important information on the system and the
ongoing process.
It contains:
• The logged-on user
• Indicators for maintenance of individual components
• Configuration or machine type
• Operating mode
• Remaining time of the current processes
• The status of the system in plain text and symbols
• Alarms in plain text and symbols
2.6.2. The toolbar

Using the (green) toolbar, you can switch between process pictures (as an
alternative to the main menu), choose the mode and start or end the production
run. Like the headline, the toolbar is displayed on each screen.
Pushbutton Function
Camera Creating a screenshot
Mode Changing the mode and the function. Enabled
from user level “servicec” and above.
Start Starting the process technology.
Stop Stopping the process technology.
Standby In hot operation, sets the system to standby
mode. The internal heaters stay active while the
external ones are deactivated.
Acknowl. Acknowledging of alarms.
End Ends the current production run and starts the
cleaning procedure.
Main Calls the main menu.
Overview Calls the “overview” window.
Process Calls the “process” window.
Product. Calls the “production” window.
Quality Calls the “quality” window.
Trending Calls the “trending” window.
Depending on the system type or the current mode, some of the pushbuttons may
be deactivated. The Standby function, for example, is only possible with type “Uni”
systems in hot operation.
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FAS4 User Manual
2.6.3. The main screen
Depending on the selected window, the system shows the actual displays of the
selected window on the main (blue) screen. It is possible, for example, for various
from the current production, the schematic process picture or the machine
parameters to be located here. Refer to the next few chapters for an exact
description of the individual windows.
2.7. Indicators
Status indicators represent in an easily visible way the operating status conditions of the
FAS4 using different colours and animations. The following indicators are used:
2.7.1. Status indicators on the headline

The indicators on the headline refer to the general status of the FAS4. They are
located next to the text displays for status and alarm:
Off/stopped
Disturbance/alarm
Starting of the systems/preparation
Ready for operation/ready for
production
Production
2.7.2. Traffic light indicators in the “Produktion” window

In the production overview, there is one traffic light indicator (two with twin
machines) with the following status conditions:
Off Fault Preparation Ready Production
2.7.3. Status indicators of the process engineering

The indicators for process engineering shown below are used in the process
overview:

Off Fault Preparation OK/active
2.7.4. Status indicators of the heating system

If you preselect the heating system (Uni systems only), the heating icon
is displayed on the headline. The following colours are defined for the heating's
status conditions:
Heating Warm-up Internal Warm-up All

preselected/ phase/standby temperature phase/start temperatures
stop OK/standby OK
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FAS4 User Manual
3. The process pictures of the FAS4

In the visualization sub-system, there are various process pictures for control, set-up and
maintenance of the FAS4. Access to the process pictures depends on the user level. Whereas
the system only shows operators a few pictures, users at the Service level can access virtually
all pictures and also change parameters and settings. In the next chapter, we will explain the
various process pictures and show you the access options for the different user levels.
3.1. Process overview

In the process overview, the system displays all the process engineering setpoint and
process values (SP and PV). The status conditions of the process engineering units are
shown with the aid of the indicators that were described in the previous chapter. This
means that users can easily get an overview of the current status of the system and the
production run. This page is structured like the FAS4 and is divided into the following
areas: “external 1”, “process 1” and “buffer tank area”. With twin systems, the “process
2” and “external 2” columns are also activated.
To start a new production run, operators can use the “production” pushbutton at the
bottom edge of the screen to enter production parameters and to start the production
run.
Whereas operators cannot change the other values in the process overview, users from
the Service level and above can alter the set point values for the applying quantity, the
temperatures and the air pressure. To do this, you must click on the set point value you
want to change and enter a new one using the screen keyboard that the system displays.
Apart from this, service users can use the pushbutton next to the “production” one
to start the metering procedure. In the screenshot, this pushbutton is deactivated, since
it is not available to the operator.
3 - The process pictures of the FAS4 17

3.2. Production overview
The production overview shows important data on the applying quantity and the quality
of application during the production run. The page is divided into “process 1” and
“process 2” with the right-hand page only being used with Twin systems. With Uni
or Cold systems, only the “process 1” side is ever active.
Within the process sides, the window is further subdivided into three other areas.
The “external” area shows the speed of the Maker and the rod length. In the “internal”
area, the system shows the set point and process values for the applying quantity
(SP = set point value, PV = process value). Value XD describes the percentage deviation
of the process value from the set point value. This deviation is shown in graphic form in
the bottom area of the screen and is the measure of the quality of application. The red
lines in the diagram are the limit values for the deviation of the applying quantity that
are set in the alarm limits.
The traffic light indicator shows the current operating status of the system
(see Chapter 2.7.2).
3.3. Process
On the “process” screen, the system shows the process engineering of the FAS4
in schematic form. Here too, the screen is divided in a similar way to the structure of the
FAS4 being subdivided into the “external 1” and “external 2” and “process 1” and
“process 2” areas as well as “buffer tank area” and “flavourtank”. With single-rod
systems (Cold Classic and Uni Classic), the system only displays the “process 1” and
“external 1” areas in each case. “External 2” and “process 2” are only present with
double-rod systems.
The symbol is below are used on this screen:
Pump Heating/temperature
P Pressure sensor Motor
Through flow meter Valve
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FAS4 User Manual
In the bottom area of the screen in the “buffer tank area” section, the system displays
the flavour tank (on the right) and the cleaning tank (on the left). The coloured
rectangles represent the fill levels of the two tanks. The grey pipes show the connections
between the process technology and change colour to yellow – depending on the
current operating status if there is cleaning agent in the pipes – and to green if the pipes
are filled with flavour. If the system is stopped, however, the pipes are always grey.
The pipes lead from the two tanks to the left to “process 1” (with Twin systems, to the
right too to “process 2”) and there they pass the pump, the pressure sensor and the
through flow meter. Depending on the mode, it goes from there to the nozzle or back
to one of the two tanks. In addition to the icons for the through flow meter, the pump,
the pressure sensor and the heaters, the system displays the corresponding set point
(SP) and process values (PV).
At the right edge of the screen in the “flavourtank” section, the external tank is
displayed. However, this is only the case if the tank is actually connected; otherwise, this
area is deactivated. Below the tank, there is the “connect” pushbutton. If you click on it,
the FAS4's coupling starts up and makes the connection to the tank. If you follow the
pipe to the valve in front of the flavour tank on the screen, you see the pushbutton for
automatically filling the internal tank. During production, you should always activate this
function so that the internal tank is always filled automatically by the external one.
From user level “service” onwards, users can switch the system to manual mode. In this
case, the system displays “manual” as information next to the process icons and users
can click on the process icons to manually activate or deactivate the connected
equipment. For more detailed information on manual mode, refer to Chapter 6.2.

3.4. Quality recording
The quality diagram shows the percentage deviation of the applying quantity from the
set point value over time. The system displays the deviation as a blue line for the PE1
side and as a yellow one for the PE2 side (PE2 with Twin systems only). The red lines
reflect the limit values for through flow deviation that are set in the alarm limits
(generally a 3% deviation).
The data for quality trending is archived on the FAS4 for one month. Using the
pushbuttons under the graphs (<<,<,>,>>,>|), you can shift the time axis of the diagram
and in this way view the current data as well as the data of past production runs. Clicking
on the “online” pushbutton allows you to switch between the current recording and
loading of data from the archive. Using the selection menu on the right, you can also
change the resolution of the timescale between 1 min and 24h. If you want to read out
exact values from the diagram, you can display a moveable pointer by clicking on the
“cursor” pushbutton. When you move the cursor along the time axis, the system
displays the current data for the respective instant.
3.5. Trending
In trending, the system displays the
most important process data in graphic
form. It has a similar structure to
quality recording; however, it differs in
as much as it is possible to represent
up to six different absolute values here.
You can choose the values you want to
display using the six selection menus at
the bottom edge of the screen. All the
data in trending is archived on the
FAS4 for one month. Directly below the
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FAS4 User Manual
diagram, there are various pushbuttons and menus that allow you to shift the time axis
or to change its resolution. Using the “cursor” pushbutton, you can display a pointer to
query the exact values of the individual curves in the diagram.
3.6. Maintenance menu

3.6.1. Filters and hoses
You should maintain the filters and hoses of the FAS4 on a regular basis. For this reason,
there are corresponding menus in the maintenance window.
In the menu, you can see the maintenance intervals for the filters and hoses, the time
remaining until they are next maintained and a pushbutton to acknowledge
maintenance.
The maintenance interval for the hoses is fixed at two years. Two weeks before this
period expires, the system issues a warning to inform you that maintenance is necessary
in the near future. If the time expires, an alarm is generated and you can no longer start
the system. After replacing the hoses, a Service level user can acknowledge maintenance
and reset the remaining time.
You must define yourself the interval for maintaining the two filters. The time depends
on the through flow rates at which you are producing and how badly your flavour is
contaminated. However, you should initially set very short intervals (4-8h) and then
observe how badly the filter clogs. If you see that the filter is only slightly contaminated
or not at all, you can slowly increase the times. In addition, you can recognize clogged
filters by the fact that the pump speed increases and the application quality reduces.
Once you have cleaned the filters, click on the “maintenance accomplished” pushbutton
to reset the remaining time until the next maintenance procedure back to the set
interval.

If a maintenance interval has expired, the icon on the menu changes colour to yellow.
At the same time, the corresponding icon on the headline also changes colour to yellow
to display the fact that maintenance is necessary in the other windows too.
Carry out maintenance on the filters on a regular basis. Clogged filters lead
to a reduction in the quality of application and in a worst case situation
damage the pump.
Due to contact with the flavour, the hose connections in the FAS4 can age,
which means that you should replace them after the specified time. Old pipes
can leak and burst.
3.7. Statistics
For quality control, the FAS4 records various data at runtime.
This includes, for example, the operating hours of the pump, the switching cycles of the
valves or the total amount of flavour that was applied.
Users can view the data at any time but cannot reset most of the counters, since some
of the information is important for fault analysis and can only be cleared by Köhl Service
staff.
3.8. Alarms
If alarms or warnings are pending, the system informs you of this in the headline of each
process picture. In each case, the system displays the current message in red if it
is an alarm and in orange if it is a warning. The time when the message was issued
is shown to the left of the message text. The indicator on the right next to the message
bar flashes in the appropriate colour when an message is issued. Whereas warnings are
only informative and have no effect on production, the machine enters the stop status
in the case of an alarm.
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FAS4 User Manual
Example alarm:
Example warning:
To get an exact overview of all the pending warnings and alarms, operators call the
“alarm” window via the main menu or the toolbar.
Here, the system displays all the current messages in chronological order. Using the
filters at the bottom edge of the screen, you can selectively filter by warnings or alarms.
After changing the selected filter, you must update the view by clicking on the “acquire”
pushbutton. Using the “acknowl. all” pushbutton, you can acknowledge the messages in
a similar way to clicking on the “Acknowledge” pushbutton on the toolbar. The FAS4 has
an alarm archive that archives all the messages for one month. To open the archive, click
on the “alarm history” pushbutton.

3.9. Alarm history
The alarm history shows all the messages that occurred over a freely definable time
period.
To determine the desired time period and the messages (warnings or alarms) that you
want to display, use the input fields at the bottom edge of the screen. To update the
view, then click on the “acquire” pushbutton.
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FAS4 User Manual
4. Set-up and Parameterization

From user level Service and above, it is possible to change the settings and parameters of the
FAS4. The windows and options for doing this are explained in this Chapter.
4.1. Machine parameters

In the “machine parameter” window, you can change various times and control values
for different processes. The parameters are sorted by location and you can select them
using the tabs in the top area of the screen. The tabs that are available depends on the
FAS4 model. Usually with single-rod machines, only the “external 1”, “process 1” and
“buffer tank area” tabs are available. Tabs “process 2” and “external 2” are only used
with double-rod (Twin) systems.
Using the “export” and “import” pushbuttons, you can copy the data records to a USB
stick and import them to other systems.
4.1.1. External 1
On tab “external 1”, you will find the parameters for the external area of the FAS4.
This includes the hose package and the nozzle.
Hand
The manual value specifies the manipulated variable that is used to control all the
actuators in the “external 1” area. In the case of systems with heaters, this
includes the heaters for the hose package, the nozzle and the rail. In the case of
cold systems or when running without heaters, this value is not needed.
Warmup
Here, you can set the reheating time for the external areas. This time is intended
to ensure that all the flavour is liquefied in the hose package and the nozzle and
4 - Set-up and Parameterization 25

that there are no blockages. After the FAS4 has been started and the set point
temperatures have been reached, this time starts to count down.
Delay air valve

After switching from production to ready for production, transportation of flavour
to the nozzle is immediately interrupted. To prevent dripping from the nozzle, you
can set a delay time for the air valve here. The system then blows the nozzle clear
for a moment before the air is switched off.
Spraying delay (Windg)

In the case of nozzles for application to paper, the control air and the process air
for the nozzle must first be switched on. Not until this has happened, does the
system switch over the winding and route the flavour to the nozzle. Set the desired
delay time for the winding here. The delay time has the effect of smoother
application starting and avoiding stains at the start of production.
Offset temperature nozzle X (Filter)

With filter makers this offset is added to the temperature input of the nozzle X
automatically. The value is to compensate for the high temperature loss of this
nozzle.
4.1.2. Process 1
The “process 1” area includes all the process technology on the left-hand side of
the FAS4 containing, for example, the pump and the valves. In this area, you also
define the times for the different production and cleaning procedures.
Hand
The manual value specifies the manipulated variable for the actuitors of process
side 1 of the FAS4. These include the pump and the heating of the assembly plate,
for example.
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FAS4 User Manual
Cleaning circulation
The time and set point value for the cleaning circulation after ending a production
run.
Spray cleaner
Set the time here for spraying cleaning agent while cleaning the nozzle.
Displace cleaner
On starting a production run, flavour is pumped for a specific time from the flavour
tank towards the cleaning tank. This displaces the cleaning agent from the last
production run and prevents contamination of the flavour with cleaning agent.
Flavour circulation
Before the system reaches the “ready for production” status, flavour is first
circulated. This ensures that the pipes are filled evenly with flavour and prevents
air bubbles that can lead to careless application. Set the desired time and the set
point value for this process here.
Spray flavour
The time and set point value for spraying flavour, e.g. at manual metering.
Displace flavour
After ending a production run, the system first displaces the flavour from the pipes
to the flavour tank using cleaning agent. On the one hand, this wastes less flavour
while on the other, the cleaning agent is less contaminated by flavour. You should
not choose too high a time setting and set point value; otherwise, cleaning agent
could get into the flavour tank.
Max. power pump

Here, you set the maximum power of the installed pump. This can be 120, 240 or
480 g/min, for example. The value is set once at commissioning of the system and
only Köhl staff members can change it.
Warmup (hot operation only)

Here, you set the system's reheating time. It is not possible to start the pumps
until all the set point temperatures have been reached and the time set here has
expired. At this location, you cannot change the value; instead, change to the
“buffer tank area” if you want to set another value.
You must not choose a warmup time that is too low; otherwise, there is
no guarantee that the complete flavour has melted. Flavour components
that have not melted can result in damage to the system.

Retire flavour
When applying hot flavour and if the maker stops, the pump is run slowly
backwards after the time set here to draw the flavour from the nozzle back into
the pipe. This prevents flavour from cooling on the unheated tip of the nozzle and
producing overpressure at restarting. The flavour is drawn back with the set
manipulated variable until the quantity set under “set point value” is reached.
Retire cleaner
After cleaning the nozzle, the cleaning agent from the tip of the nozzle is sucked
back into the pipe. To do this, the system controls the pump with the set
manipulated variable until the quantity set under “set point value” is reached.
4.1.3. Flavor change during operation
A Flavour change can be carried out at the cigarette machine.
The plant or plant parts must be switched completely de-energized,

WARNING
and protected against intentional and unintentional restart!
4.1.4. Buffer tank area
The following parameters apply to the “buffer tank area”:
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FAS4 User Manual
Hand
Set the control value here for the actuators in the buffer tank area of the FAS4
in manual mode.
Warmup (hot operation only)

Here, you set the FAS's reheating time. At warm-up, the system keeps heating until
all the set point temperatures have been reached. After this, the set time expires
to ensure that the flavour has melted completely. You must not set the time too
low, since the solid flavour components can damage the system.
Time to auto-standby
During readiness for production of the FAS4, the system pumps flavour in the
circulation to be ready for operation at any time. If the Maker is out of service for
a relatively long period, however, it is sensible to stop the pumps to avoid
unnecessary wear. This means that after the time set here, the system
automatically switches to standby mode. With the heating system activated, the
system then switches off the pumps and the external heaters.
4.1.5. Process 2, External 2

These two tabs are only available in Twin systems. The parameters are similar to
the ones for “process 1” and “external 1”.
4.2. Control circuits

The FAS4 has a large number of controllers for the pumps and heaters. You can set
the control response using parameters Kp, Tn, Tv and Td and observe it in the
diagram.
Using the scroll arrow , you can choose the desired controller. The system
automatically updates the diagrams and parameters in the window.

Before changing the controller settings, you should familiarize yourself with the
following terms:
SP: Set point – The set point value of a process value.
PV: Process value – The current process value of
a controller.
CV: Control value – The current manipulated variable
of the controller.
Kp: The proportional component of a controller.
Generates a control value (CV) that is
proportional to the deviation (SP-PV) for an
actuator. If the Kp is too high, this can lead to
hunting of the controller.
Tn: Integral action time or reset time of a controller.
While there is a deviation (SP-PV), the system
continues to increase or reduce the manipulated
variable (CV) for an actuator. The lower the
integral action time is the faster the controller
becomes while under certain circumstances
tending to hunting.
Tv, Td: The rate time damping time of a controller.
Together, they determine the differential
response of the controller. Tv = 0 deactivates the
differential-action component of the controller.
4.2.1. Controller settings

All the controller parameters are set at manufacture of the system and checked
again at commissioning and set to meet local requirements. Under some
circumstances, however, it can be sensible to readjust the controller (for example
if a pump is worn out or with a different flavour). When setting the controller, you
should note the following:
• When making changes to a parameter, always do it in very small steps.

• A higher Kp has the effect of controlling the actuator more strongly. This
can lead to the control response being faster; however, it responds more
strongly to disturbances and tends to hunting.
• A lower Tn leads to faster correction or the manipulated variable while also
often resulting in hunting of the controller.
• In general, you should not change Tv and Td.
• You can tell that a controller is set correctly if the process value (PV)
follows the setpoint value (SP) without delay while at the same time
overshooting only slightly or not at all and stabilizing to the setpoint value
within an acceptable time. Do not try to set the controller “unnecessarily”
fast. Making major changes to the manipulated variable always places
a strain on the system and above all on the pump.
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FAS4 User Manual
Below, there are a few examples of different controller settings using the
controller for the flavour circulation as an example:
Kp = 4.20 In this example, the controller is set

Tn = 0.22 very fast. Kp is high whereas Tn is very
Tv = 0.09 low. This leads to the controller
Td = 0.01 strongly overshooting and not settling
even after reaching the set point
value. The controller would respond
very strongly to changes in the set
point value or disturbances due to an
air bubble, for example. In this case,
you should increase Tn and/or reduce
Kp.
Kp = 2.60 The controller responds in a stable

Tn = 1.00 manner after reaching the set point
Tv = 0.09 value but is very sluggish on the
Td = 0.01 whole. You should set the controller
faster by reducing the Tn value.
Kp = 2.60 The process value follows the set

Tn = 0.42 point value at a very short interval and
Tv = 0.09 does not overshoot. This example is
Td = 0.01 intended as an ideal reference for
your controller when making settings.
When setting your controller, keep to the recommendations in this

manual. Apart from this, note that many controlled systems are very
sluggish, which means that you may not notice changes to parameters
straight away. This applies in particular to the internal heating
controllers and the heaters for flavour and cleaning agent. Strong
overshooting of the temperatures can lead to the destruction of the
system or the flavour.

4.2.2. Controller overview
Using the “controller overview” pushbutton, you
can open an overview window containing the
activated and deactivated controllers. If a controller
is deactivated, the corresponding process is
switched-off and the associated warnings and
alarms are ignored. With a cold (Classic) system, for
example, all the temperature controllers are
switched off and only the controller for the pumps
are active. Another example is that when
connecting a filter machine, the heater for the rail
(external Y) is generally deactivated, since this
heating circuit is not present. If you want to run a
Twin system as a single-rod machine, you can
deactivate one of the two pumps. Then, the system only uses the respective other
process side for production. In this connection, it does not really matter whether
you use PE1 or PE2.
The FAS4 saves the combination of activated and deactivated controllers at
calibration of the Maker. When doing this, the FAS4 specifies a separate data
record for each Maker. This means that you can save different combinations that
are automatically loaded when you connect the corresponding Maker. For
example, if you take the FAS4 from a filter maker and connect it to a cigarette
maker, the system automatically reactivates the controllers for the rail heater if
they were previously activated on the cigarette maker.
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FAS4 User Manual
4.3. Alarm limits

All the process values of the FAS4 are monitored according to the following concept:
tHH
Y(t)
SP 1 2
PV
In the alarm limits, six parameters are set for each process value. The high and low levels
(1) are limit values; the system generates a warning if they are exceeded or fallen short
of. This warning first shows that there is a deviation between the process value and the
set point value. The next stage are the highlight and lowlow level (2). If these values are
exceeded or fallen short of, a countdown starts. If the process value does not return
below the limit value within the set HH or LL time (tHH), the system issues an alarm and
the plant is stopped.
You set the individual levels and timers in the “alarm limits” window that you can open
via the main menu from the Service level onwards. In the same way as with the machine
parameters, the individual parameters are sorted by location and you can export and
apply them on other systems using the “export” and “import” pushbuttons.
The alarm limits protect the system from damage and your production
from bad-quality application. This means that you should carefully
consider the limit values that you choose. If one particular alarm is
issued more frequently, you must clear up the causes of the malfunction.

4.3.1. External 1
In the “external 1” area, you can find the parameters for the external plant
sections. In this case, these include the Maker and the hose package.
Power ext. machine (absolute limit values)

Set here the limit values for the Maker's speed signal.
• LL - level: Monitoring of the incremental encoder signal. If the start signals
for the FAS4 from the Maker and the speed signal is <= LL - level, the
system generates an alarm after the set time has expired.
• L - level: Below the speed set here, the system generates a warning. On the
other hand, the FAS4 does not start until this speed has been exceeded
to avoid false starts.
• H - level: Should be set such that it matches the Maker's maximum speed.
If the value exceeds this threshold, the system generates a warning.
• HH - level: Should be somewhat above the H limit value. If exceeded, the
FAS4 switches off.
Temperaturediff. (systems with heating only, absolute differential value)

Here, you can set the limit values for the external temperatures. This includes the
hose package, the nozzle and the rail. Temperature monitoring is started after
warm-up if the temperature is in a valid range.
• LL - level: If the temperature set point value is below the difference to the
set point value set here, the system generates an alarm when the set LL -
time has expired and switches off.
• L - level: On falling below this temperature difference, the system
generates a warning.
• H - level: On exceeding this difference to the set point value, the system
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FAS4 User Manual
• HH - level: On exceeding this temperature difference, the system generates
an alarm after the HH - time has expired and switches off the plant.
4.3.2. Process 1
Here, you can find the parameters for the left-hand process side of the FAS4.
Speed pump (absolute limit values)

Set the limit values for the pump speed here. They do not depend on the model
of pump.
• LL - level: Must be set to “0”, since no minimum speed is provided.
• L - level: Must be set to “0”, since no minimum speed is provided.
• H - level: From the speed set here onwards, the system generates
a warning.
• HH - level: Set the upper speed limit here. If the value is exceeded, the
system issues an alarm after the set time HH - level.
Diff. massflow flavour (relative differential values)

Here, you set the limits for the deviation between the through flow process value
and the through flow set point value.
• LL - level: If this limit value is fallen short of, the system issues an alarm and
the plant is stopped after the set LL - time.
• L - level: On falling below this limit value, the system generates a warning.
• H - level: On exceeding this limit value, the system generates a warning.
• HH - level: If this limit value is exceeded, the system issues an alarm and
the plant is stopped after the set time.
System pressure
• LL - level: Must be set to “0”, since there is no minimum system pressure.
• L - level: Must be set to “0”, since there is no minimum system pressure.

• H - level: If the pressure rises above this value, the system generates
a warning.
• HH - level: If the pressure rises above this value, the system issues an alarm
and the plant is stopped after the set HH - time. Note that the maximum
pressure for FAS4 is 10bar. This means that the HH value should be set to
a maximum of about 9.8 bar.

Here, you can set the limit values for the temperatures of process side 1.
Monitoring is started after warm-up if the temperatures are in a valid range.
set point value set here, the system generates an alarm when the set LL -
time has expired and switches off.
Difference density (absolute limit values – not with M54 through flow meters)
Here, you can set the limit values for the density that the through flow meter
measured. Using these values, it is possible to detect dry running of the pump, air
in the pipes or the wrong medium.
Sensitivity oscillation detection

The FAS4 detects oscillations in the applying quantity that can be caused by
wrongly parameterized controllers, contamination in the tank, air bubbles in the
pipes or leaky clamping points. Using the menu, you can set the sensitivity of
oscillation detection to low, normal and high. “Low” means that minor oscillations
are ignored and that the system only issues an alarm in the case of more major
variations. At the “high” stage, the alarm system also responds to minor
oscillations. As standard, you should choose the “normal” option and then adapt it
as required.
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FAS4 User Manual
4.3.3. Buffer tank area
Set here the alarm limit values for the FAS4's buffer tank area.
Difference air pressure (absolute differential values)

Here, you can set the limit values for the air pressure deviation of the pressure-
regulating valve. This air is used as the process air (spraying air) for the two-
component nozzle.
Flavourlevel (absolute limit values)

Here, you set the limits for the fill level of the internal flavour tank.
You should not change the parameters for the fill level, since they are calculated
from the tank's capacity.

Here, you can set the limit values for the temperatures in the buffer tank area.
Monitoring is started after warm-up if the temperatures are in a valid range.

set point value set here, the system generates an alarm when the set
LL - time has expired and switches off.
4.3.4. Process 2, External 2

The limit values for these two locations are only available with Twin systems. Their
function is similar to those of the “process 1” and “external 1” group. You can use
the pushbutton at the bottom edge of the screen to easily transfer the parameters
between groups 1 and 2. The system then copies the parameters directly between
the process sides.
4.4. Calibration
An incremental encoder supplies a current signal of between 0 and 20 mA
to synchronize the FAS4 with the connected Maker. To enable the FAS4 to establish
a relationship between the current signal and the current machine speed, you must
carry out calibration for each Maker. The FAS4 can save this calibration for up to 16
different Makers and call it automatically when it is connected to a different machine.
This means that to be able to differentiate between different Makers, each onoe is given
a code that is hard-wired in the connecting socket for the FAS4. To view the calibration
data or to carry out a new calibration process, call “calibration” from the main menu.
In the table, you can easily see which Makers the FAS4 is already calibrated on. For this,
the first column contains the code from 0 to 15, with the second one containing the
Maker's freely selectable ID. The “X” in columns three to five indicates the type of
Maker. Filter makers, cigarette makers or winding machines. Column six and seven show
the Maker's maximum speed. However, the value in column six is just the theoretical
speed value at 20mA and must not necessarily match the Maker's maximum speed.
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FAS4 User Manual
Column eight indicates whether the machine in question is a single- or double-rod one.
In the right-hand column, the “X” indicates which Maker is currently connected and that
can be calibrated.
To start a new calibration process, click on the “calibrate”

pushbutton at the bottom edge of the screen. The system now
displays a dialog box in which you can enter an ID for the
Maker. To do this, use the screen keyboard that the system
displays automatically after you click on the input field.
Clicking on the “next” pushbutton to go to the next dialog box.
For the FAS4 to be calibrated to the Maker's speed, it must be

running at a constant speed. You have achieved a good
calibration result if the Maker runs at about half the maximum
speed. Since the FAS4 is connected to the Maker, it can only be
started when the FAS4 issues the enable. To do this, click on
the “Enable” pushbutton and starten the Maker. The easiest way to carry out calibration
is when the machine is running with no material.
Now, specify the Maker in question. With filter makers and

winding machines, the speed is normally stated in m/min.
With cigarette makers, this is stated in pcs/min (cigarettes
per minute). After clicking on the appropriate pushbutton,
the system opens the dialog box for the actual calibration
process. Enter the required data in this box.
At calibration in m/min, first enter the Maker's

maximum speed in the top input field. If the Maker now
runs at a constant speed, read this off the Maker and
enter it in the middle field. Then click on the “calculate”
pushbutton. The FAS4 now calculates the Maker's speed
from the entered data and the current value that the
FAS4 measured and enters it in the bottom field. This
value should match the one that you read off the Maker.
If this is the case, click on the “accept” pushbutton to
complete calibration. If the value does not match, cancel
the procedure and repeat calibration.

If you want to calibrate the FAS4 on a cigarette
maker, first enter the Maker's maximum speed here
too. If the Maker now runs at a constant speed,
enter in the next two fields the stick length and the
Maker speed you read-off. If all the values are
correct, click on the “calculate” pushbutton. The
FAS4 calculates the speed from the entered data
and the current value of the incremental encoder
and displays it in the bottom field. If the value
matches the one you read-off, you should run the
Maker at a lower and at a higher RPM speed as a
test; in both cases, compare the calculated value
with the displayed one. If the values match over the
whole RPM speed range, you can save the calibration by clicking on the “accept”
pushbutton. Otherwise, cancel calibration and repeat the procedure. If necessary, you
must check the connection to the Maker.
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FAS4 User Manual
5. Producing Using the FAS4 (Production Mode)
5.1. Introduction
You can use the FAS4 in different ways to apply flavour. The first differences are whether
the system is connected to a machine for cigarettes, filters or paper and what type
of flavour you want to apply. Ultimately, these variants only result in slight adjustments
to the process. FAS4 users do not have to adapt themselves when the machine
is changed. Basically, there is no change in the preparatory work for production and the
procedure in the FAS4.
5.2. Preparation
In general, the FAS4 is ready for operation without any major preparation. However, you
should have carried out the following steps before starting production to ensure that
it is not hampered and you can start without delay.
1. Connect the FAS4 to the Maker. To do this, connect the connecting plug to the
cigarette maker, filter maker or winding machine and also make the connection
to the air supply.
2. Switch on the FAS4 and the Maker.
3. Check the fill levels of the tanks
a. With cold flavours, you can now fill the tanks with fresh cleaning agent
and flavour; if necessary, you can also connect the external tank to the
FAS4. With cold flavours, you can also have the internal tank filled
automatically by directly connecting the external tank.
b. If you are using hot flavour, you must generally warm up the system
before filling with cleaning agent and/or flavour. This means that you
must wait until the system is hot before filling up.
4. Connect the nozzle to the Maker. Always route the hose package such that it is
not kinked and is protected from damage.
5. Prepare the Maker in accordance with your specifications.
6. As the next step, you enter the production parameters in the FAS4 and start the
system.
Manual Cleaning
The container of the FAS4 and the external tank car may only be opened
in the kitchen sauces (place for Flavor filling) in the space provided and
not in the production area when using flammable liquids.
Danger of explosion
In ATEX zone, the FAS4 must not be electrically connected!
5.3. Entering the production parameters and starting production

You specified the type of Maker that the FAS is connected to at calibration (Chapter 4.4)
and you do not need to enter it again before production. Entering the production
5 - Producing Using the FAS4 (Production Mode) 41

parameters is slightly different and we will explain it below for each variant. However,
the first and most important setting is whether the heating is activated or not (Uni
systems only).
5.3.1. Cold/warm operation and key switches

In cold operation, it is possible to process flavours that are normally liquid and
must not be melted by being heated. These can be materials that are dissolved in
alcohol or glycerine.
You must preselect warm operation for flavours that are solid at room
temperature and must be liquefied. These materials include natural menthol, for
example.
You switch the heaters on and off using the key switch on the front panel door
of the FAS4. The following settings are possible:
The key switch is in the basic position. The heater and the agitator
are not enabled.
In this position, you enable the agitator in cold operation.
Turning the key from the basic setting to the right activates the
heater. After finishing a production run or restarting the system,
the heater is automatically deactivated. In this case, you must turn
the key back to the basic position and then to the right again. If the
key is in the right-hand position, this does not automatically mean
that the heater is activated. If the heater is active, the yellow
“heating preselected” lamp is lit up on the front panel door of the
FAS4 and the heating icon is displayed on the FAS4's headline.
Example: Heating not activated:
Example: Heating activated:
After the FAS4 has started or an ongoing production run has ended, for safety
reasons cold operation is always preselected automatically and with this, the
heaters are switched off. This is intended to prevent flammable materials being
heated by accident.
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FAS4 User Manual
Note the setting of the key switch and whether the heaters are activated
or not. You must never heat flammable materials. When processing hot
materials, the heater must be switched on.
After you have checked the status of the

heater, carry on entering the production
parameters. To do this, open the “Overview”
dialog box and click on the “production”
pushbutton at the bottom of the box. Note
that the pushbutton is only active if the FAS4 was calibrated with the connected
Maker.
5.3.2. Entering the production parameters (cigarette maker)

For applying flavour to the tobacco rod in a cigarette maker, you must enter the
stick length value, the applying quantity value and possibly the temperature value.
If the heater is not activated, the system automatically deactivates the field for the
temperature. You always enter the topmost parameters first; only then, are the
bottom ones active.
Create a screenshot
Name of the connected Maker
Setpoint temperature [°C]
Stick length [mm/pcs]
Applying quantity [g/10³pcs]
Select SP for the flavour circulation in

production readiness of the Maker.
Start production
Close
After clicking on the “Start” pushbutton, the FAS4 starts production preparation.
5.3.3. Entering the production parameters (filter maker)

For applying flavour to the filter tow in a filter maker, you must also enter the stick
length value, the applying quantity value and possibly the temperature value.
If the heater is not activated, the system automatically deactivates the field for the
temperature. You always enter the topmost parameters first, only then are the
bottom ones active. The input of the applying quantity value can be entered in
filter maker in g / 10²pcs or in g / 100m.

Create a screenshot
Applying quantity [g/10²pcs] or [g/100m]

Start production
Close
5.3.4. Entering the production parameters (winding or paper machine)

If the FAS4 is calibrated to a winding machine, you can choose between two
variants for entering the production parameters. As with the filter machine, you
can enter the applying quantity in g/10²pcs or switch to percentage input.
Create a screenshot
Name connected Maker of the

Switching between applying quantity units
Applying quantity [g/10²pcs]

Start production
C
l
ose
When you click on the pushbutton to switch between applying quantities, the
input fields change as follows:
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FAS4 User Manual
Create a screenshot
Switching between applying quantity units
Tobacco weight per rod [mg]
Flavour amount in the tobacco [%]
Start production
Close
5.3.5. FAS4 production preparation
After you click on “Start”, the FAS4 starts to run through various production steps.
Before the system is ready for production, the following steps are made:
1. Warmup (if the heater is activated)
The internal and external heaters are started. As soon as the temperatures are
in the range of the set point temperatures, the system starts a reheating time
to be on the safe side. After this time has exceeded, the system proceeds to the
next step.
2. Cleaning circulation
The system pumps cleaning agent through the pipes for a predefined time
to clean them and to remove possible flavour residue.
3. Displace cleaner
In this step, the pump sucks in flavour and pumps it into the cleaning tank. This
displaces the cleaning agent from the pipes and it does not get into the tobacco
at a later time.
4. Flavour circulation
In the flavour circulation, the system sucks flavour out of the tank and pumped
back there. This displaces air bubbles from the pipes and mixes the flavour.
5. Production readiness
During production readiness, the FAS4 in the flavour circulation waits for the
Maker to start. If the FAS4 is ready for production, the yellow lamp on the front
panel door lights up and the enable signal for the Maker is issued. You can now
start the Maker and carry out production. As soon as cigarettes or filters are
being produced, the FAS4 changes to production and sprays flavour through the
nozzle.
For more detailed information on the individual steps, refer to Chapter 6.3.

During production, the headline shows the current step and the time to the next step in
each case.
While the yellow indicator next to the step is flashing, the FAS4 is not yet ready. You
cannot start the Maker until the indicators are continuously yellow.
You can set the times and setpoint values for the different steps in the machine
parameters (see Chapter 4.1).
5.4. Production
When the FAS4 is ready for production, it waits until the Maker has started and reports
that it is producing. At the same time, the FAS4 switches to production mode and starts
applying flavour. You can see when the FAS4 is producing on the headline and the
corresponding entry and the green LED next to the text:
If the Maker stops the production run, the system automatically switches back to
production readiness or flavour circulation waits until the Maker sends the production
signal again.
5.4.1. Switching on the agitator

Cold operation
In cold operation, you must enable the agitator using the key switch before
switching it on. To do this, turn the switch to the left-hand position. Once you have
done this, the system displays a message in the FAS4. This informs you
that agitating is only allowed with non-flammable materials. Due to
sparking at agitation, it is possible for flammable materials to explode.
You must only agitate non-flammable materials. Otherwise, there is

a danger of explosion at agitation due to sparking.
After the agitator has been enabled, you can switch it on in the
“Process” window using the pushbutton next to the tank. If an
external tank is connected, the agitator is switched on automatically
there.
Warm operation
Before you can switch on the agitator in warm operation, all the internal
temperature setpoint values must have been reached. If this is the case and the
corresponding security time has expired, the system enables the pushbutton for
switching on the agitator on the “Process” screen (see above). If the system stops,
the agitator is also switched off automatically. It is not necessary to enable using
the key switch in warm operation.
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FAS4 User Manual
5.4.2. Standby and auto standby
During production readiness, the FAS4 pumps flavour in a circulation so that
it is always ready to produce. If the heaters are activated, they stay switched on
and maintain the set point temperature. If it is apparent that the FAS4 will not
be producing for a relatively long period of time, e.g. due to problems with the
Maker, you should stop the FAS4 (in cold operation) or switch it to standby mode
(warm operation). The appropriate pushbutton to do this is on the toolbar.
In standby mode, the pumps are stopped with the temperature still being
maintained, however. This saves the pumps and ensures a longer service life. Apart
from this, the external heaters are switched off in standby mode, which saves
energy. If you restart production, you just need to click on the “Start” pushbutton.
The auto standby function automatically changes to standby mode if you do not
produce anything for a specific time. You can set this time in the machine
parameters (see Chapter 4.1.4).
If the Maker is stopped for a relatively long period, you should stop the
FAS4 if it is running in cold operation or switch to standby mode if the
heaters are active. This avoids unnecessary wear to the pumps.
5.4.3. Setting the air pressure for the two-component nozzle

If you are operating the FAS4 on a cigarette maker with a two-component nozzle,
you must set a specific air pressure using the air control valve. Without this air, the
flavour would not be atomized; rather, it would hit the tobacco rod as a hard
spray. This means that correct application of the flavour would not be possible,
since it would lead to the rod breaking and the Maker being contaminated.
In general, the working air pressure is between 1.2 and 1.8 bar; however, it can
differ slightly and you must adjust it in dependence on the tobacco and the
flavour. You can set the set point value for the air control valve
from the Service level onwards in the “Overview” window.
To do this, click on the air control valve icon and enter the
desired value.
With cigarettes, the set air pressure affects the occurrence of spotting. If many
of these stains occur, the flavour is penetrating too far into the tobacco rod. In this
case, you must reduce the air pressure somewhat. On the other hand, if there are
stains on the front (facing the nozzle), you must increase the air pressure slightly.
Some spotting on cigarettes is normal. In general, it dries within a few minutes and
leaves no traces.
To make sure that you do not carry out production with no compressed air at all by
mistake, the system issues a message when you start the system if the the set
pressure is below 0.5 bar.
In the case of filter makers, the air pressure can be set to 0, since no compressed
air is needed for the filter nozzle.

5.4.4. Retiring flavour
The FAS4 has the “retire flavour” function so that flavour cannot remain in the
nozzle and cannot drip or set if there is an interruption to production. If the system
detects that the Maker has stopped, it slowly runs the pump backwards after
a specific time (see Chapter 4.1.2). This pulls the flavour back out of the nozzle into
the pipe and it cannot cause any more problems. If you frequently have blocked
nozzles – particularly with filter systems – you should check the set time and the
set point value for the quantity and adjust them if necessary.
5.5. Ending production

To end a production run in orderly way, click on the “End” pushbutton on the toolbar.
Then, the FAS4 starts the cleaning cycle and carries out the following steps:
1. Displace flavour
The pump sucks in cleaning agent and pumps it for a short time towards the
flavour tank. This presses the flavour in the pipe between the tank and valve back
into the flavour tank and does not contaminate the cleaning agent in the cleaning
tank.
2. Cleaning circulation
The system pumps cleaning agent in the cleaning circulation for a specific time.
This cleans the pump, the through flow meter, the valves and pipes and removes
flavour residue.
3. Clean nozzle (optional)
After the cleaning circulation, the system displays a pop-up window in which you
are prompted whether you want to clean the nozzle or not. If you click on “Yes”,
the system pumps cleaning agent through the hose package and the nozzle for
a short time. After this, the system sucks back the cleaning agent in the “retire
cleaner” function such that the nozzle does not drip while it is not in use. Before
clicking on “Yes” to confirm the pop-up dialog, ensure that the nozzle has been
dismounted and is in a vessel of some kind. Otherwise, cleaning agent runs into
the Maker.
After completing cleaning, the FAS4 prompts you whether you want to shut down the PC
or not. If you want to switch off the FAS4 after cleaning, confirm the prompt; otherwise,
click on “No”. You can also shut down the system later using the “shutdown”
pushbutton in the main menu.
Always end a production run by clicking on the “End” pushbutton so that you
can clean the system after production. Hot menthol in particular can expand
and damage the FAS4's process technology.
You must shut down the PC before switching off the FAS4. Otherwise, there
is a risk of data loss and damage to the file system.
After ending a production run, all the production parameters are reset and the heating
preselection is cleared. If you want to carry out production with heaters next time, make
sure that you enable the heating again (see Chapter 5.3.1).
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FAS4 User Manual
6. Operating modes
After starting the system, production mode is always selected by default. However, in addition
to production mode there are various other modes for testing and maintenance.
To change modes, you must first log on as a Service

level user. After this, you can call the window for
changing operating modes by clicking on the “mode”
pushbutton in the main menu. As an alternative, it is
possible to use the pushbutton of the same name
on the toolbar at the top right.
Im the operating mode window, you can see the following modes from right to left:
production, hand (manual), semi with its various functions and auto mode at the extreme
right.
6.1. Production mode

In production mode, all the processes in the FAS4 run automatically. You must only
enter various production parameters at starting of a production run. Handling
production mode was described in the previous chapters.
6.2. Manual operation

Whereas the system is controlled on a fully automatic basis in production mode,
in manual mode virtually all the automatic features are deactivated. Under some
circumstances, this is desirable for testing, maintenance and diagnostics. In manual
mode, you can manually switch all the actuators on or off and control them using a fixed
control value. You can, for example, control the pump at exactly 25% power or control
a specific heating element with any control value.
The most important screen in visualization during manual

operation is the “process” screen. Here, the system
displays all the process engineering actuators, pipes and
values. You can see the actuator that you can control in this
situation by the fact that a text box is displayed next to the
actuator containing the text “hand”. When not being
controlled, the devices are displayed in grey. As in this
example, when you click on the pump it is switched on and
changes colour to green. You can specify the various
actuators in the machine parameters (Chapter 4.1)
or adjust at any time on the controller screen (Chapter 4.2).
In manual operation, the SP plays no part, since it is under open-loop control rather than
closed-loop control. Only CV and PV are important here.
6 - Operating modes 49
In manual operation, the system is not monitored according to the alarm limit
value concept (see Chapter 4.3); this means that in manual mode, you
yourself are responsible for any damage due to faulty operation.
Manual mode must only be used by trained personnel for testing and
maintenance.
After switching to manual mode, all the actuators including the heaters are
switched off. This means that you must bear in mind that the system cools
down and flavour can set again before switching on the pump or the valves.
6.3. Semi operation or semi-automatic

Manual mode and semi-automatic mode differ by virtue of the fact that in semi-
automatic mode the system carries out control automatically; however, you can choose
one of the fixed steps, start it or stop it. Apart from this, the system is protected from
damage again by the alarm limit value concept.
If you change to semi-automatic mode, you can choose one of the following process
steps:
6.3.1. Cleaning circulation

In the cleaning circulation, the pump sucks cleaning agent
out of the cleaning tank and pumps it back to the cleaning
tank through the pipes. This cleans the corresponding
pipes, the pump, the system pressure sensor, the through
flow meter and the valve block.
6.3.2. Spray cleaner

If you choose “spray cleaner” and it starts, the pump
sucks cleaning agent out of the cleaning tank and pumps
it through the nozzle. This function can be used to clean
the hose package and the nozzle. Always ensure that you
dismount the nozzle from the suction line track and keep
it in an appropriate vessel; otherwise, cleaning agent will
run into the Maker.
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FAS4 User Manual
6.3.3. Displace cleaner
In this step, flavour is sucked in from the flavour tank and
pumped through the pipes to the cleaning tank. Using this
function, you can displace old cleaning agent from the
pipe back to the cleaning tank and fill the pipe with
flavour.
6.3.4. Flavour circulation

In the flavour circulation, flavour is sucked out of the
flavour tank and pumped back into the same tank. This
mode is highly suitable for flushing air bubbles out of the
pipes. These bubbles can occur after cleaning the filters
or lifting the tank cover.
6.3.5. Spray flavour

In “spray flavour” mode, flavour is pumped out of the
flavour tank through the nozzle. The function is highly
suitable for displacing cleaning agent out of the hose
package after cleaning and filling it with flavour. As an
alternative, you can also use the function for manual
metering. Before starting, ensure that the nozzle has
been dismounted and is kept in an appropriate vessel.
6.3.6. Displace flavour

Using this function, cleaning agent is sucked in and
pumped into the flavour tank. This makes it possible
to completely remove flavour from the pipe of the flavour
tank and to fill it with cleaning agent.
6 - Operating modes 51
6.4. Automatic
Automatic mode functions like production mode; however, you can use it for testing
if a Maker is not connected. All the other procedures are the same as with production
mode.
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FAS4 User Manual
7. Cleaning
You must always carry out a cleaning cycle each time you end a production run. In some
cases, e.g. when changing flavours, it can be sensible to clean the FAS4 manually so as
not to transfer any flavour.
Cleaning of the FAS4 mainly depends on the flavour that you are using. If you are using
crystalline flavour, you must first warm up the system. You generally use a cleaning
agent that resembles the flavour's carrier. For example: alcohol with alcohol-soluble
flavours or water with hot menthol.
Manual Cleaning
The containers of FAS4 and the external tank are only allowed to get
opened in the provided place of the flavour kitchen (place of flavor filling)
and NOT in the production area, while using flammable liquids.
Danger of explosion
In ATEX-area the FAS4 must not be electrically connected.
If you use flammable materials, the FAS4's heaters must not be switched on.
In hot operation, use non-flammable materials.
The automatic cleaning can be performed on the cigarette making machine.

In case that flammable gases should originate inside the FAS4, the Gas warning system
will disconnect the area of the buffer tank from tension.
After the initial cleaning, the nozzles must be purified again with clean water.
Make sure that the nozzles are thoroughly rinsed!
7 - Cleaning 53
7.1.1. Manual Cleaning
IRRITATING SUBSTANCES
Wear protective clothing when cleaning always. The protective
clothing must be approved for the respective hazardous zone!
CAUTION
• Safety glasses or a protective mask
• gloves
• Rubber boots
DANGER OF SCALDING
Danger of scalding caused by hot water.
The FAS4 can be cleaned with hot water or ethanol.
CAUTION
By cleaning the machine with water, you have to make sure that the
temperature is below the melting point of the flavors.
You will reach temperatures above 50 degree Celsius.
Wear protective clothing to be secured from hot water!
Cleaning of the machine depends on the used kind of flavor.

In case of usage of a crystalline flavor, the plant has to be heated up first. It’s not
allowed to use flammable cleanser. The choice of the cleanser depends on the kind of
flavor and should be equal to the carrier of the flavor.
DANGER OF EXPLOSION
WARNING When cleaning hot equipment, only non-flammable cleaners must be
used!
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FAS4 User Manual
7.1.2. Cleaning the external tank
Disconnect the external tank

from the station
1. Electrically disconnect the

external tank from the
station.
2. Loose the brake of every

wheel.  (2x)
3. Unlock the mechanical

clutch .
7 - Cleaning 55
4. Pull the external tank as long
as the plug becomes visible
and easily reachable.
5. Unlock the plug with the

help of the safety hooks.
(2x)
6. Pull the plug  off.
The external tank is

disconnected from the
station now.
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FAS4 User Manual
7.1.3. Completely empty the tank
To empty the tank completely, you need an empty container.
1. Open the door of the

external tank.
2. Pull the pipes  out of the

opening.
3. Put the pipes  into the

empty container.
4. Open the ball valve 

approx.. 75%
1
75%
The flavor runs into the

container.
5. Close the ball valve , after

the tank has been
completely discharged.
BLOCKED HOSE
If you use hot flavor, which does not or just slowly flow off, it might
IMPORTANT
be that the hose is blocked by cooled down flavor.

In this case, use a hot air gun until the flavor can flow off.
7 - Cleaning 57
6. Remove the filtering candle.
Turn of the seal 
completely.
Pull out the filtering candle
with the help of the star grip.

Pull out the filter candle

vertically!
7. Clean the filter candle with

ethanol or hot water. The
water temperature has to be
lower than the melting point
of the flavors.
CAUTION
Danger of scalding! Wear

protection clothes!
Put attention on the O-rings .

They must not get damaged!
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FAS4 User Manual
8. Clean the inside of the tank

with a sponge.
Mind to destroy anything

inside the tank during
cleaning.
9. Let the rest of the cleanser

flow off though the hose.
 „Empty the tank
completely!“
Crystallized menthanol
Cooled down menthanol crystallizes. To clean the tank, heat it up again.
BURN HAZARD
If you heat up the methanol, the inside of the tank becomes very hot.
There is a risk of burns.
WARNING
Wear protection clothes!
Let the tank cool down again to secure yourself from burns.
7 - Cleaning 59
7.1.4. Clean the wires
1. Let the proper cleaner stay in

the tank.
2. Place an empty container

under the closure coupling
3. Press the shutter clutch with

a blunt tool.
Hint:
 Allen key.
The spring looses it’s tension –

the rest of the flavor will be
pushed through the cleanser of
the pipes.
Indicates a dangerous situation when they cannot be avoided,

CAUTION
which can lead to a minor or moderate injury.
Adhering to this advice makes effective work possible and

prevents property damage.
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FAS4 User Manual
7.1.5. Cleaning the station
The cleaning of the external tank takes place in the Flavourkitchen .
Dismount the tank as follows:
Don’t forget the transport top!

IMPORTANT The transport top is a part of FAS4.
 • 1 x for the buffer tank – Flavors
• 1 x for the buffer tank – Cleanser
 Buffer tank
 Cover plate
 Mounting plate
 Hooks for the plates
WARNING
1. De-energize the plant!
2. Loose the screw plug  (2x).
3. Hang the cover on the hook


4. Put the cover plate on the

tank. .
5. Fasten the screw plugs! 

(2x).
7 - Cleaning 61
7.1.6. Cleaning of the filter
There are screwed filters under

the cover plates (buffer and
cleaning tank).
To clean the filter, we

recommend to demount the
pipes inkl. filter.
1. Loose the pipes and the

filters from the plate. .
Fix the pipes  , during

screwing them out!
2. Drag out the pipe 

together with the filter.
Clean the pipes and the filters

with hot water.
CAUTION
Danger of scalding!
Wear protection clothes!
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FAS4 User Manual
8. The External Flavour Tank (Optional)

The external flavour tank is a standalone system for preparing flavour and ensuring that
production is carried out without interruptions. You can connect the FAS4's internal tank
directly via a coupling, which makes it possible to automatically top up the internal tank when
a specific fill level is fallen short of.
8.1. Construction
The external tank is structured as follows:
Connecting plug
Filler hole
Filter cartridge
Unlocking of the FAS4
Control panel
Maintenance door for electrical
enclosure
Brake
8.2. The control panel

You use the control panel to control the external tank. With cold tank trucks, there
is no control panel, since the FAS4 controls the few electrical functions.
Temperature setpoint specification and process value
Switch on tank
Switch for the agitator
Key switch for heating preselection
Switch off tank

Warm-up function
Alarm lamp
8 - The External Flavour Tank (Optional) 63

8.3. Filling
To open the external tank, open the
lock and fold the lid forwards. Now put
in your liquid or solid flavour. The best
way to do this is to use the optional
funnel with integrated filter. When
filling, observe the maximum fill level
and ensure that no flavour runs past
the filler neck into the buffer tank area.
The container opening of the external container truck may only be opened in
the flavor kitchen (place for Flavor filling) in the provided space and not in the
production area.
Each time before filling, ensure that the ball valve for draining flavour
is closed. If it is necessary for the flavour you are using, wear personal
protective clothing.
8.4. Melting and preparing the flavour

You can either connect the external tank directly to the FAS4 or prepare the tank in the
“sauce kitchen” and run it to the FAS4 later and connect it then. In both cases, proceed
as follows:
If you are using cold flavour, no special measures are necessary. After filling the flavour,
the tank is ready for operation.
If you need to heat and melt solid flavour, please put it in. After this, connect the tank
to the power supply. Now, use the key switch to choose the heating and switch on the
tank. The temperature controller will now display the the set point and process values
for the temperature and the heater starts to heat up the flavour.
The tank may only be switched on when you are using non-flammable
materials.
The tank truck has two different power stages:

1. The melting stage (warm-up): The tank heats up at full power to liquefy the
flavour as quickly as possible.
2. Heating: The tank heats up at reduced power.
After switching on the tank, the melting stage is automatically pre-selected. You can see
this because the Warm-up pushbutton is lit up. The tank now keeps heating up at full
power until the temperature is close to the setpoint value. After this, the system
switches automatically to the lower power stage. You can also manually switch the
melting stage on or off by pressing the Warm-up pushbutton. At switch on of the tank, it
is crucial to observe the following point:
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FAS4 User Manual
If the melting stage is activated and the tank is only partially filled or the
flavour is already warm, a very high temperature overshoot can occur. This
means that at switch on of the Warm-up function and of the tank, you must
observe the fill level and the temperature of the flavour. Since the Warm-up
function is automatically activated when you switch on the tank, you should
switch off this function if necessary.
If the flavour has reached its setpoint temperature, you can switch off the tank,
disconnect it from the power supply and run it from the “sauce kitchen” to the FAS4.
If the tank is already connected to the main unit, continue with connecting the process
technology.
Full tanks are heavy and may tip over due to the unfavourable centre
of gravity. This means that you should never run full tanks down ramps
or over bumps. Whenever you are transporting tanks, ensure that the lid
is always closed.
8.5. Coupling to the FAS4

To connect the tank to the main unit, first make the electrical connection. Observe the
position of the key switch with the external tank. If the heater is switched on on the
FAS4, you must also switch on the heater on the external tank before connecting.
After connecting the plug, you can

now run the tank truck up to the
main unit and engage it. When
doing this, the FAS4's brakes should 1
be locked. Ensure that the main unit
and the tank truck are on level
ground and that there are no
objects under the wheels. The tank
is engaged when you can no longer
pull it away from the FAS4 without
activating the unlocking mechanism. 2
After making the electrical and mechanical connections, you can now connect the
process technology. To do this call the process picture in the FAS4.
After connection, the system automatically
displays the external tank. To carry out coupling,
now click on the “connect” pushbutton. Note that
you can only connect with the heater activated
if the temperatures are in the setpoint range.
If coupling was started successfully, the coupling
icon changes to green; if there was an error,
it would change colour to red. If there are
8 - The External Flavour Tank (Optional) 65

problems coupling, refer to Chapter Maintenance chapter of the Headfile for more
information.
Apart from the filler valve, the process picture contains the pushbutton for activating
automatic filling. If the fill level is low, this function automatically opens the filler valve
and tops up the internal tank until it is full again. Use this pushbutton to manually switch
on or off.
8.6. The agitator

Before you can switch on the agitator in hot operation, the set point temperature must
have been reached and a safety time must have expired. As soon as the agitator
is enabled, the corresponding pushbutton on the control panel starts flashing. In cold
operation, the agitator is automatically switched on at the same time as the internal
agitator in the FAS4 is switched on.
8.7. Cleaning
For information on cleaning the external tank, please refer to Cleaning 0.
66
9. The Additional Screen (Optional)
9.1. Introduction
Using the additional screen, users can operate the FAS4 regardless of their position in
the system. To do this, the additional screen shows a mirror image of FAS4 visualization
and allows the same user inputs on the touchscreen as on the FAS4 itself. If you install
the additional screen directly on the Maker users can see both machines without leaving
their workplace.
The additional screen is an IPC based on Windows CE with a touchscreen and front USB
connection. It is supplied with a robust adjustable socket that you can easily install in the
production area (e.g. directly on the Maker). To start the monitor, you just need to make
the connection to the FAS4 via the connecting cable or the Harting plug. The operating
system and the client software start automatically and are ready for operation within
a very short time. You can carry out operation via the additional screen as soon as the
system displays the same image as on the FAS4.
User inputs on the additional screen or on the FAS4 result in the other screen being
automatically blocked for two seconds in each case. This prevents people making inputs
on both screens at the same time and causing faulty inputs.
The USB front connection is looped through directly to the PC of the FAS4 and you can
also use it for saving screenshots or parameters in the same way as a direct connection
on the FAS4.
To switch off the additional screen, you only need to disconnect from the FAS4 or,
if necessary, to switch off the FAS4's main switch. If you do not need the additional
screen, you can park it on the FAS4.
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FAS4 User Manual
9.2. Connection between the monitor and the FAS4
The illustration shows the connection between the monitor and the FAS4. The plugs
have two pins for the 24V power supply and the plug for the Ethernet cable.
Communication between the additional screen and the FAS4 is via a 1 Gbit network
connection. This makes it possible to cover long distances between the monitor and the
and to implement secure data transfer by means of the TCP/IP protocol.
If you connect a USB device to the additional screen's front USB port, the connected
device is treated as if it were directly connected to the FAS4 IPC.
9.3. Using the monitor on several FAS4 units

You can use an additional screen on a flexible basis on any prepared systems and makers
you like. It is not necessary to permanently assign the monitors to a specific FAS4.
9.4. Troubleshooting
Problem Possible solution
The additional screen does not start up ! Check the power supply and the +ET – 3F3
fuse
! Check all the plug-in connections
! Make sure that the FAS4 is switched on
The additional screen starts up but does not display ! Check the network connection between
FAS4 visualization the FAS4 and the additional screen. At the
bottom right of the additional screen on
the task bar, the system must display the
network icon and the “Connected” status.
The additional screen's mouse pointer responds ! Carry out calibration again. To do this,
incorrectly to user inputs. open the maintenance window on the
FAS4 and click on the monitor icon to open
monitor calibration. Now, calibrate the
FAS4's monitor first and then the
additional screen.
9 - The Additional Screen (Optional) 69

10. FAS4 diagnosis view (optional)
The diagnosis view provides some useful tools for debugging and shows an overall status
of the machine. It can be accessed via the maintenance menu.
10.1. Main view

The main view of the diagnosis screen is a schematic chart representing the structure of
the system. It shows the major electrical and pneumatic devices as interconnected
boxes.
A failure of a single device or a device group is indicated by red flashing boxes and
connections.
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FAS4 User Manual
Often there are consecutive faults if main devices fail. If that is the case It‘s common
practice to start investigation at the first faulty device of the chain. Detailed diagnostic
information can be accessed by clicking on boxes.
Detail UPS Detail serial terminal
Detail modbus terminal Detail analogue output
10.2. Configuration of interface terminals

In addition to diagnostic information a button for initial configuration of communication
terminals is available. This applies to Beckhoff (KS6041/KS6001) terminals used for
interfacing with pump and flow meters. After replacing of one the terminals clicking the
button starts the configuration process. A red flashing corner indicates the routine being
executed. After the configuration process the indicator turns green again.
10 - FAS4 diagnosis view (optional) 71

10.3. Schematics
In some cases, e.g. on valve failures, the user is assisted by corresponding abstracts from
electrical diagrams or pneumatic schemes.
10.4. Examples
10.4.1. Air supply failure
- The air pressure sensor in the FAS4 detects low pressure

- The corresponding box flashes red
- As switching valves and air control valves rely on correct air pressure they are
supposed to be not working as well. So they are also flashing red.
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FAS4 User Manual
10.4.2. Failure of analogue input
Analogue inputs connect sensors for system pressure, pressure control valve and filling.
On failure of an analogue input the corresponding box and following boxes are flashing
red to indicate errors or possible consecutive faults. To start investigation the analogue
input detail view should be opened by clicking on its box.
In this case it’s pretty obvious that channel 1 of terminal 5A5 shows “Underrange”. This
means the input current dropped below 4mA. This can be caused by a broken sensor or
just wrong wiring.
0- 73
11. Recording production data (optional)
After the machine has been

configured with „Production Data“ you
can give an extra “Batch ID" .
The recording of the data starts with
the start of the production.
IMPORTANT
The following steps are only visible for
user with level “servicem”!
Open the maintenance menu.
Push the “production data download”
 to open the “Production- Data-
Window”.
Note:
The “Production- Data-Window”
shows the data per day.
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FAS4 User Manual
 – delete production data

 – export the production data
Tip
You can select several data.
After confirmation the delete button a

safety request has to be confirmed
too.
A successful delete will be shown in a

window.
11 - Recording production data (optional) 75

Also a successful export will be show.
A window shows if no production data

was found.
IMORTANT Data will delete automatically after 365 days.
76
FAS4 User Manual
12. Glossary
Additional An optional additional screen for operating the FAS4 from the Makeraus.
screen
Metering At metering, a check is carried out of whether the through flow meter is
correctly calibrated and is working precisely. When doing this, the system
sprays flavour for a defined time and it is caught in a measuring jug. After
this, the flavour in the measuring jug is weighed and compared with the
FAS4's result.
Automatic A function for automatically filling the internal flavour tank through the
filling external tank. At a low flavour level, the system automatically opens the filler
valve and closes it when the tank is full.
Auto After a settable time, the FAS4 automatic stops the pump and switches to
standby standby mode. If activated, the internal heaters stay switched on.
Classic FAS4 model for single-rod makers
system
Cold system An FAS4 model that can only process cold flavour
CV Control value the manipulated variable for an actuator.
ET The electrical enclosure in the FAS4. Amongst other things, it contains the
power supply, various fuses and devices.
FAS4 Flavor Application System
g/10²pcs A unit for the amount of flavour with filters; it corresponds to grammes per
100 sticks.
g/10³pcs A unit for the amount of flavour with cigarettes; it corresponds to grammes
per 1000 cigarettes.
Kp The proportional component of a controller. Generates a control value (CV)
that is proportional to the deviation (SP-PV) for an actuator. If the Kp is too
high, this can lead to hunting of the controller.
PE0 Process engineering 0, process area 0; the FAS4's internal processing
chamber.
PE1 Process engineering 1, process side 1; seen from the front, the left-hand
process side of the FAS4.
PE2 Process engineering 2, process side 2; seen from the front, the right-hand
process side of the FAS4.
PV Process value, process actual value.
SP Set point, process set point value.
Tn Integral action time or reset time of a controller. While there is a deviation
(SP-PV), the system continues to increase or reduce the manipulated variable
(CV) for an actuator. The lower the integral action time is, the faster the
controller becomes. Under some circumstances has a tendency to hunting.
Tv, Td The rate time damping time of a controller. Together, they determine the
differential response of the controller. Tv = 0 deactivates the differential-
action component of the controller.
Twin system An FAS4 model for single-rod and double-rod Makers.
12 - Glossary 77
Uni system An FAS4 model that can process and apply both cold and warm flavour.
UPS Uninterruptible power supply, i.e. the battery of the FAS4.
Warm-up A function of the external tank to quickly melt flavour. Under certain
function circumstances, this should be switched on.
XC1 External 1, external area 1; in general, includes the hose package and the
nozzle as well as possibly the nozzle heater and the rail.
XC2 External 2, external area 2; in general, includes the hose package and the
nozzle as well as possibly the nozzle heater and the rail (XC2 with Twin
systems only).
XD Deviation between the set point and process values.
78
FAS4 User Manual
13. Alarm messages

Message Possible cause Fault remedy
ET error gas warning unit ? Fault in the gas sensor ! Check the sensor
ET gas alarm ? The gas warning unit is still initializing ! Ventilate the system and determine the cause
? Alarm due to a high gas concentration ! Check the pipes/connections for leaks
ET RCCB has tripped ? A residual current has been detected ! Inspect the system for damage
? Electrical devices damaged ! Inspect the wiring
? Wire break
ET emergency STOP ? The emergency STOP button has been pressed ! Unlock the emergency STOP button and
acknowledge the fault
FAS4 air pressure monitoring ? The supply air pressure has dropped below 4.1 bar ! Check the air pressure on the maintenance unit and
turn it up if necessary
! Check the feed lines to the FAS4
! Check the internal pneumatic lines
Communication error between Visu/PLC ? Error in communication between the PLC and the ! Acknowledge; if the message does not go away,
visualization system restart the system
24V AC fuse error ? The fuse for the 24V AC supply of the heaters has ! Check the system for damage
tripped ! Check for a wire break
! Eliminate the cause of the error and acknowledge it
24V DC fuse error ? A fuse for the 24V DC supply has tripped ! Check the system for damage
! Check for a wire break
PE0 230V AC heater fuse error ? A fuse for the 230V AC supply of the heaters has ! Check the system for damage
PE0 filler valve error ? The filler valve is not switching correctly ! Check the air pressure
! Check the pneumatic lines and the electrics
! If necessary, clean the valve
PE0 high alarm air pressure deviation ? The pressure of the air control valve is too high ! Check the control valve
PE0 high alarm flavour tank temperature difference ? The temperature of the flavour is too high ! Check the fill level
! Check the controller parameters
! Check the temperature of the external tank
PE0 high alarm filler valve temperature difference ? The temperature of the filler valve is too high ! Check the controller parameters
! Check the seating of the heating cartridge and the
13 - Alarm messages
FAS4 User Manual
feeler
PE0 high alarm internal temperature difference ? The internal temperature is too high ! Check the heating fan
! Check the temperature sensor
PE0 high alarm cleaning tank temperature difference ? The temperature of the cleaning agent is too high ! Check the fill level
PE0 high alarm connection temperature difference ? The temperature of the connection with the ! Check the coupling
external tank is too high ! Check the controller parameters
sensor
PE0 low alarm flavour level ? The flavour fill level is too low ! Top up the flavour
! Make the connection to the external tan and
activate automatic filling
! Check the line from the external tank for air
bubbles
PE0 low alarm air pressure deviation ? The pressure of the air control valve is too low ! Check the supply air
! Check the pneumatic lines
! Check the control valve
PE0 low alarm flavour tank temperature difference ? The temperature of the flavour is too low ! Check that the flavour tank is correctly seated
! Check the heating plate and the sensor
! Check the temperature of the external tank
PE0 low alarm filler valve temperature difference ? The temperature of the filler valve is too low ! Check the heating cartridge and the sensor
PE0 low alarm internal temperature difference ? The internal temperature is too low ! Close the doors of the FAS4
! Check the hot air blower and the sensor
PE0 low alarm cleaning tank temperature difference ? The temperature of the cleaning agent is too low ! Check that the cleaning tank is correctly seated
! Check the heating plate and the sensor
PE0 low alarm connection temperature difference ? The temperature of the connection with the ! Check the coupling
external tank is too low ! Check the controller parameters
sensor
PE0 max. level of cleaning agent ? The cleaning tank is too full ! Remove cleaning agent
PE0 min. level of cleaning agent ? There is too little cleaning agent in the tank ! Top up the cleaning agent
13 - Alarm messages
FAS4 User Manual
PE0 emergency switch off flavour tank overtemperature ? The temperature of the flavour tank is too high The ! Check the seating of the flavour tank
heater is switched off for safety reasons ! Check the fill level
! Check the heater and the sensor
PE0 emergency switch off filler valve overtemperature ? The temperature of the filler valve is too high. The ! Check the seating of the heating cartridge and the
heater is switched off for safety reasons sensor
PE0 emergency switch off internal overtemperature ? The internal temperature is too high. The heater is ! Check the hot air blower and the sensor
switched off for safety reasons ! Check the controller parameters
PE0 emergency switch off cleaning tank ? The temperature of the cleaning tank is too high. ! Check the seating of the cleaning tank
overtemperature The heater is switched off for safety reasons ! Check the fill level
! Check the heater and the sensor
PE0 emergency switch off connection overtemperature ? The temperature of the connection with the ! Check the seating of the heating cartridge and the
external tank is too high The heater is switched off sensor
for safety reasons ! Check the controller parameters
PE0 temperature of flavour PT100 is defective or does ? Sensor error or wire break ! Check the sensor for defects or a wire break and
not exist replace it if necessary
PE0 temperature of filler valve PT100 is defective or ? Sensor error or wire break ! Check the sensor for defects or a wire break and
does not exist replace it if necessary
PE0 temperature of flavour tank heater PT100 is ? Sensor error or wire break ! Check the sensor for defects or a wire break and
defective or does not exist replace it if necessary
PE0 temperature of cleaning tank heater PT100 is ? Sensor error or wire break ! Check the sensor for defects or a wire break and
PE0 temperature of internal PT100 is defective or does ? Sensor error or wire break ! Check the sensor for defects or a wire break and
PE0 temperature of cleaning agent PT100 is defective or ? Sensor error or wire break ! Check the sensor for defects or a wire break and
PE0 temperature of connection PT100 is defective or ? Sensor error or wire break ! Check the sensor for defects or a wire break and
PE1 suction valve fault ? The suction valve is not switching correctly ! Check the air pressure
PE1 throughflow meter fault ? The throughflow meter issues an error or ! Check the throughflow meter
communication is disturbed ! Check communication If present, the LEDs on the
throughflow meter and on the Modbus card
(KS6041) must flash quickly. If necessary, replace
the KS6041.
13 - Alarm messages
FAS4 User Manual
PE1 servo drive fault ? The pump motor issues an error ! Check the wiring
! Check the pump
PE1 high alarm density deviation ? The density of the medium is higher than it was set ! Check the limit values
in the alarm limits ! Check the valves
! Check the filters
PE1 high alarm difference in flavour throughflow ? The throughflow is too high ! Check the controller parameters
! Check the lines, valves and filters
PE1 high alarm pump RPM speed ? The pump is RPM is too high ! Check the system pressure
! Check the lines, valves and filters for leaks or
clogging
! It may be that the pump is worn out and you must
replace it
! Check the nozzle
PE1 high alarm system pressure ? The system pressure is too high ! Check the pipes for kinking or blockages
! Check the nozzle and clean it if necessary
! Check the external heaters/temperatures
! Check the valves and clean them if necessary
PE1 high alarm mounting plate temperature difference ? The temperature of the mounting plate is too high ! Check the heater and the sensor
PE1 winding fault ? The winding is not switching correctly ! Check the air pressure
PE1 low alarm density deviation ? The density of the medium is lower than it was set ! Check the lines for air bubbles and that they are
in the alarm limits tight
! Check the valves
! Check the filters
! Check the limit values
PE1 low alarm difference in flavour throughflow ? The throughflow amount is too low ! Check the filters and clean them if necessary
! Check the lines and the nozzle and clean them or
get rid of the air bubbles if necessary
! Check the pump for wear
13 - Alarm messages
FAS4 User Manual
PE1 low alarm pump RPM speed ? The pump RPM speed is too low ! Check the alarm limit value
PE1 low alarm system pressure ? The system pressure is too low ! Check the alarm limit value
PE1 low alarm mounting plate temperature difference ? The temperature of the mounting plate is too low ! Check the heater and the sensor
! Close the doors of the FAS4
PE1 motor overvoltage ? The voltage of the pump motor is too high ! Check the motor's power supply
PE1 motor overcurrent ? the pump motor is drawing too much current ! Check the system pressure in operation
! Clean the filters
! Check the lines, valves and filters and clean them if
necessary
! Check the seating of the pump head
PE1 motor overtemperature ? The pump motor is too hot ! Check the system pressure in operation
! Clean the filters
necessary
! Check the temperature setpoint values
PE1 emergency switch off mounting plate ? The temperature of the mounting plate is too high. ! Check the heater and the sensor
overtemperature The heater is switched off for safety reasons. ! Check the controller parameters
PE1 pump is blocked >> pump diagnostics ? The pump is blocked ! Call pump diagnostics
! Check the pump head and flush it if necessary
! Check the pump motor
! Replace the pump
PE1 return valve fault ? The return valve is not switching correctly ! Check the air pressure
PE1 oscillation alarm difference in flavour throughflow ? The throughflow amount is fluctuating greatly ! Check the nozzle and the filters and clean them if
necessary
! Check the controller settings
! Check the lines
PE1 safety valve fault ? The safety valve is not switching correctly ! Check the air pressure
PE0 temperature of mounting plate heater PT100 is ? Sensor error or wire break ! Check the sensor for defects or a wire break and
13 - Alarm messages
FAS4 User Manual
PE1 temperature of pump PT100 is defective or does ? Sensor error or wire break ! Check the sensor for defects or a wire break and
PE1 overtemperature of pump heater ? The pump heater has got too hot ! Check the seating of the pump heater
! Check the heating cartridge and the sensor
! Check the temperature setpoint values of the
heaters
PE1 switching valve fault ? The switching valve is not switching correctly ! Check the air pressure
PE2 suction valve fault ? The suction valve is not switching correctly ! Check the air pressure
PE2 throughflow meter fault ? The throughflow meter issues an error or ! Check the throughflow meter
communication is disturbed ! Check communication If present, the LEDs on the
throughflow meter and on the Modbus card
(KS6041) must flash quickly. If necessary, replace
the KS6041.
PE2 servo drive fault ? The pump motor issues an error ! Check the wiring
! Check the pump
PE2 high alarm density deviation ? The density of the medium is higher than it was set ! Check the limit values
in the alarm limits ! Check the valves
! Check the filters
PE2 high alarm difference in flavour throughflow ? The throughflow is too high ! Check the controller parameters
PE2 high alarm pump RPM speed ? The pump is RPM is too high ! Check the system pressure
! It may be that the pump is worn out and you must
replace it
! Check the nozzle
PE2 high alarm system pressure ? The system pressure is too high ! Check the pipes for kinking
! Check the nozzle and clean it if necessary
! Check the external heaters/temperatures
! Check the valves and clean them if necessary
13 - Alarm messages
FAS4 User Manual
PE2 high alarm mounting plate temperature difference ? The temperature of the mounting plate is too high ! Check the heater and the sensor
PE2 winding fault ? The winding is not switching correctly ! Check the air pressure
PE2 low alarm density deviation ? The density of the medium is lower than it was set ! Check the lines for air bubbles and that they are
in the alarm limits tight
! Check the valves
! Check the filters
! Check the limit values
PE2 low alarm difference in flavour throughflow ? The throughflow amount is too low ! Check the filters and clean them if necessary
! Check the lines and the nozzle and clean them or
get rid of the air bubbles if necessary
! Check the pump for wear
PE2 low alarm pump RPM speed ? The pump RPM speed is too low ! Check the alarm limit value
PE2 low alarm system pressure ? The system pressure is too low ! Check the alarm limit value
PE2 low alarm mounting plate temperature difference ? The temperature of the mounting plate is too low ! Check the heater and the sensor
! Close the doors of the FAS4
PE2 motor overvoltage ? The voltage of the pump motor is too high ! Check the motor's power supply
PE2 motor overcurrent ? the pump motor is drawing too much current ! Check the system pressure in operation
! Clean the filters
necessary
! Check the seating of the pump head
PE2 motor overtemperature ? The pump motor is too hot ! Check the system pressure in operation
! Clean the filters
necessary
! Check the temperature setpoint values
PE2 emergency switch off mounting plate ? The temperature of the mounting plate is too high. ! Check the heater and the sensor
overtemperature The heater is switched off for safety reasons. ! Check the controller parameters
PE2 pump is blocked >> pump diagnostics ? The pump is blocked ! Call pump diagnostics
! Check the pump head and flush it if necessary
! Check the pump motor
13 - Alarm messages
FAS4 User Manual
! Replace the pump

PE2 return valve fault ? The return valve is not switching correctly ! Check the air pressure
PE2 temperature of mounting plate PT100 is defective ? Sensor error or wire break ! Check the sensor for defects or a wire break and
or does not exist replace it if necessary
Maintenance interval of hose system has expired ? The maintenance interval for the hoses has expired ! Replace the hoses and acknowledge maintenance
in the maintenance window
XC1 24V AC heater fuse error ? The fuse for the external 24V heaters has tripped ! Check the external heating circuits for damage or
wire break
XC1 high alarm output of external machine ? The Maker's speed signal is higher than possible by ! Check the connection to the Maker and carry out
calibration recalibration
XC1 high alarm nozzle temperature difference ? The temperature of the nozzle is too high ! Check that the seating of the nozzle is correct
XC1 high alarm temperature difference of external X ? The temperature of the rail heater is too high ! Check the seating of the heating cartridge and the
sensor
XC1 high alarm temperature difference of external Y ? The temperature of the rail heater is too high ! Check the seating of the heating cartridge and the
sensor
XC1 high alarm temperature difference of hose package ? The temperature of the hose package is too high ! Check the hose package for damage
XC1 low alarm output of external machine ? The speed signal from the Maker is too low ! Check the connection to the Maker
! Carry out calibration again.
XC1 low alarm temperature difference of external X ? The temperature of the rail heater is too low ! Check the seating of the heating cartridge and the
sensor
XC1 low alarm temperature difference of external Y ? The temperature of the rail heater is too low ! Check the seating of the heating cartridge and the
sensor
XC1 low alarm temperature difference of hose package ? The temperature of the hose package is too low ! Check the hose package for damage
XC1 emergency switch off overtemperature of nozzle ? The temperature of the nozzle is considerably too ! Check that the seating of the nozzle is correct
high The heater is switched off for safety reasons ! Check the heating cartridge and the sensor
13 - Alarm messages
FAS4 User Manual

XC1 emergency switch off overtemperature of external ? The temperature of the rail heater is considerably ! Check the seating of the heating cartridge and the
X too high The heater is switched off for safety sensor
reasons ! Check the controller settings
Y too high The heater is switched off for safety sensor
XC1 emergency switch off overtemperature of hose ? The temperature of the hose package is ! Check the hose package for damage
package considerably too high The heater is switched off for ! Check the controller settings
safety reasons
XC1 tachogenerator signal is faulty ? The speed signal from the Maker is faulty ! Check the wiring of the incremental encoder from
the Maker to the FAS4
! Carry out calibration again.
XC1 temperature of nozzle PT100 is defective or does ? Sensor error or wire break ! Check the sensor for defects or a wire break and
XC1 temperature of external X PT100 is defective or ? Sensor error or wire break ! Check the sensor for defects or a wire break and
XC1 temperature of external Y PT100 is defective or ? Sensor error or wire break ! Check the sensor for defects or a wire break and
XC1 temperature of hose package PT100 is defective or ? Sensor error or wire break ! Check the sensor for defects or a wire break and
XC2 24V AC heater fuse error ? The fuse for the external 24V heaters has tripped ! Check the external heating circuits for damage or
wire break
XC2 high alarm nozzle temperature difference ? The temperature of the nozzle is too high ! Check that the seating of the nozzle is correct
XC2 high alarm temperature difference of external X ? The temperature of the rail heater is too high ! Check the seating of the heating cartridge and the
sensor
XC2 high alarm temperature difference of external Y ? The temperature of the rail heater is too high ! Check the seating of the heating cartridge and the
sensor
XC2 high alarm temperature difference of hose package ? The temperature of the hose package is too high ! Check the hose package for damage
XC2 low alarm temperature difference of external X ? The temperature of the rail heater is too low ! Check the seating of the heating cartridge and the
sensor
XC2 low alarm temperature difference of external Y ? The temperature of the rail heater is too low ! Check the seating of the heating cartridge and the
13 - Alarm messages
FAS4 User Manual
sensor
XC2 low alarm temperature difference of hose package ? The temperature of the hose package is too low ! Check the hose package for damage
XC2 emergency switch off overtemperature of nozzle ? The temperature of the nozzle is considerably too ! Check that the seating of the nozzle is correct
high The heater is switched off for safety reasons ! Check the heating cartridge and the sensor
X too high The heater is switched off for safety sensor
Y too high The heater is switched off for safety sensor
XC2 emergency switch off overtemperature of hose ? The temperature of the hose package is ! Check the hose package for damage
package considerably too high The heater is switched off for ! Check the controller settings
safety reasons
XC2 temperature of nozzle PT100 is defective or does ? Sensor error or wire break ! Check the sensor for defects or a wire break and
XC2 temperature of external X PT100 is defective or ? Sensor error or wire break ! Check the sensor for defects or a wire break and
XC2 temperature of external Y PT100 is defective or ? Sensor error or wire break ! Check the sensor for defects or a wire break and
XC2 temperature of hose package PT100 is defective or ? Sensor error or wire break ! Check the sensor for defects or a wire break and
13 - Alarm messages
KÖHL Maschinenbau AG
17, Am Scheerleck
6868 Wecker
Luxembourg
+352 71 99 71 2000
FAS4 User Manual AG-MF201504-EN
www.koehl.eu

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FAS4 User Manual

FAS4 User Manual

Type code Variants Description

1.2. Safety information

1.3. Connecting to the maker

1.4. Switching on the FAS4

1.5. Switching off the FAS4

Danger of explosion caused by leakage

WARNING Every hose and every connection suffers from wear.

2. General Information On Visualization

2.1. Main menu

The elements of the main menu are as follows:

2.2. User administration

2 - General Information On Visualization 11

2.2.2. Changing the user

2.2.3. Changing your own user log-on

2.4. Online help

2.5. Switching languages

2.6. Functional structure of the display

2 - General Information On Visualization 13

2.6.2. The toolbar

2.7.1. Status indicators on the headline

2.7.2. Traffic light indicators in the “Produktion” window

Off Fault Preparation Ready Production

2.7.3. Status indicators of the process engineering

2 - General Information On Visualization 15

2.7.4. Status indicators of the heating system

Heating Warm-up Internal Warm-up All

3. The process pictures of the FAS4

3.1. Process overview

3 - The process pictures of the FAS4 17

The symbol is below are used on this screen:

3 - The process pictures of the FAS4 19

3.6. Maintenance menu

3 - The process pictures of the FAS4 21

3 - The process pictures of the FAS4 23

4. Set-up and Parameterization

4.1. Machine parameters

4 - Set-up and Parameterization 25

Delay air valve

Spraying delay (Windg)

Offset temperature nozzle X (Filter)

Max. power pump

Warmup (hot operation only)

4 - Set-up and Parameterization 27

4.1.3. Flavor change during operation

A Flavour change can be carried out at the cigarette machine.

The plant or plant parts must be switched completely de-energized,

4.1.4. Buffer tank area

The following parameters apply to the “buffer tank area”:

Warmup (hot operation only)

4.1.5. Process 2, External 2

4.2. Control circuits

4 - Set-up and Parameterization 29

4.2.1. Controller settings

• When making changes to a parameter, always do it in very small steps.

Kp = 4.20 In this example, the controller is set

Kp = 2.60 The controller responds in a stable