Aiger Flex Rmm-Arcb-mex 21114709-Operation Manual

AIGER FLEX RMM
Operation Manual
MACHINE Nr. ARCB-MEX 21114709

Aiger Engineering Ltd.
4003 Plovdiv Bulgaria
Tel./+359 32 905 000
Fax./+359 32 947 001
Email: support@aiger.com
www.aiger.com
All information listed in the following manual is property to Aiger GROUP AG Switzerland. All drawings, data, schemes, and
all kind of information listed in the operation manual belongs to Aiger Group AG Switzerland. All rights reserved. Original.
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Do NOT distribute outside the organization without prior approval and active NDA/CA in place with the designated party.
D000138680
D000138680 Technical Specifications
Rev. 02; 30.10.2018
Machine Overview – AIGER FLEX RMM
Entrance
Exit
Working product range

Filter rod length (Standard) :: 60 ÷ 150 mm
Filter rod diameter (Standard) :: 6,30 ÷7,90 mm
Customized filter rod diameter (Option) :: 5,3 ÷ 6,29 mm
Customized filter rod diameter (Option) :: 7,9 ÷ 9,0 mm
Productivity
Working speed Main Brand 300 m/min
Working speed Additional brand 350 m/min
Power supply specifications
Power consumption :: 40 kW
Nominal voltage (3 Phase) :: ~400 V
Frequency :: 50 Hz
Rated current :: 100 A
Short circuit rating :: 10 kA
Cables cross section

L1, L2, L3 :: 25 mm2
N, PE :: 25 mm2
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AIGER GROUP AG AIGER UK Ltd. AIGER Engineering Ltd. AIGER USA LLC AIGER FAR EAST Ltd.
Switzerland United Kingdom Bulgaria USA Hong Kong
D000138680
Rev. 02; 30.10.2018
Compressed air supply

Pressure :: 6±1 bar
Debit :: 20 m3/h
Compressed air connector :: Ф 13 mm
Suction exit
Suction exit connector :: 1 x Ф90 mm
Debit :: 8.1 m3/h
Machine dimensions
Height :: 2401 mm
Length :: 4351 mm
Width :: 2767 mm
Net weight :: ~3500 kg
The delivered machine might have minor differences due to the

specific chosen options and features. MTF supply
specifications/consumption is not included.
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D000138680
Rev. 02; 30.10.2018
Standard Layout – AIGER FLEX RMM
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Standard Floor Loading Diagram – AIGER FLEX RMM
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1 Technical data .......................................................................................... 1

1.1 Preface .......................................................................................... 1.1
1.1.1 Chapter objective......................................................................... 1.1
1.1.2 Chapter purpose .......................................................................... 1.1
1.2 Process description of the Rod Module ................................................... 1.2
2 Safety .................................................................................................... 2.1
2.1 Preface .......................................................................................... 2.2
2.1.2 Chapter purpose .......................................................................... 2.2
2.2 General Safety Information ................................................................... 2.3
2.3 Safety system description ....................................................................... 2.4
2.3.1 Safety sensors .............................................................................. 2.4
2.3.2 General list of applied safety sensors .......................................... 2.5
2.4 General Warnings for work area .......................................................... 2.7
2.5 Risk factors and hazards areas ............................................................ 2.12
3. Transport and installation..................................................................... 3.1
3.1 Preface .......................................................................................... 3.1
3.1.1 Chapter objective ........................................................................... 3.1
3.1.2 Chapter purpose............................................................................. 3.1
3.2 Unloading of machines ........................................................................... 3.2
3.2.1 Removing of securing elements from pallets .................................... 3.2
3.2.2 Unloading pallets from the transport vehicle ................................... 3.4
3.3 Unpacking the machine .......................................................................... 3.6
3.3.1 Opening of wooden boxes/pallets ................................................. 3.6
3.3.2 Removing aluminium thermo-foil ...................................................... 3.6
3.3.3 Removing stretch and bubble foil .................................................... 3.8
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3.3.4 Removing fixing consoles and securing straps holding machines to the
pallets ...................................................................................................... 3.9
3.3.5 Taking the machines off the pallets ................................................. 3.9
3.3.6 Disposal or storage of packing ..................................................... 3.10
3.4 Installation of the machines ................................................................... 3.11
4 Running the machine ............................................................................ 4.1
4.1 Preface .................................................................................................. 4.1
4.1.2 Chapter purpose .......................................................................... 4.1
4.2 Starting the machine............................................................................... 4.2
4.3 Normal and Emergency stoppages ........................................................ 4.4
5 Control panels....................................................................................... 5.1
5.4 Preface .................................................................................................. 5.1
5.1.2 Chapter purpose............................................................................. 5.1
5.2 RMM control panels description .............................................................. 5.3
5.2.1 Main control panel ....................................................................... 5.3
5.2.2 Additional control panel ............................................................... 5.4
5.2.3 Sampling control panel................................................................. 5.5
5.3 Traffic light ............................................................................................ 5.6
5.4 Main switch of the line ............................................................................ 5.7
5.5 Rod module pneumatic system ............................................................. 5.8
5.6 Driving system ........................................................................................ 5.9
5.7 Main drive motor ................................................................................. 5.11
5.8 Warning sensors and other type of sensors .......................................... 5.12
5.9 Sikora measuring head ........................................................................ 5.17
5.9.1 Diameter measuring principle ..................................................... 5.17
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5.9.2 Installation .................................................................................. 5.18

5.9.3 Device Calibration ..................................................................... 5.18
5.9.4 SIKORA measuring device maintenance ...................................... 5.19
5.9.5 Cleaning the CCD-sensor-line ..................................................... 5.19
5.10 Temperature sensors and heaters .................................................... 5.20
5.11 Motors ............................................................................................. 5.21
5.12 Fans ................................................................................................. 5.23
5.13 Executive mechanism ........................................................................ 5.24
5.14 General list of applied sensors ........................................................ 5.27
5.15 Operating messages........................................................................ 5.29
6 Adjustment of the machine .................................................................. 6.1
6.1 Preface.................................................................................................. 6.1
6.1.2 Chapter purpose............................................................................. 6.1
6.2 Process description of the Rod maker module ........................................ 6.2
6.3 Adjusting the timing belt ........................................................................ 6.5
6.4 Paper feed ............................................................................................ 6.7
6.4.1 Process description .......................................................................... 6.7
6.4.2 Bobbin changer............................................................................... 6.9
6.4.3 Bobbin brakes .............................................................................. 6.10
6.4.4 Splicer .......................................................................................... 6.12
6.4.5 Loop roller .................................................................................... 6.14
6.4.6 Paper guides ................................................................................ 6.15
6.4.7 Rolling guides ............................................................................... 6.17
6.4.8 Exit guide ..................................................................................... 6.18
6.4.9 Tension roller ................................................................................ 6.19
6.4.10 Splicing....................................................................................... 6.20
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6.4.10.1Process of splicing ................................................................. 6.22

6.4.10.2 Speed for performing change of the bobbins ...................... 6.23
6.4.10.3 Splice and ejection............................................................... 6.24
6.5 Gluing process ..................................................................................... 6.26
6.5.1 Process description ........................................................................ 6.26
6.5.2 Glue tank and nozzles .................................................................. 6.27
6.5.3 Start the machine .......................................................................... 6.28
6.6 Forming the filter rod ........................................................................... 6.32
6.6.1 Stages of forming the filter rod .................................................... 6.32
6.6.2 Garniture tongue adjustment procedure (steps) ............................ 6.33
6.6.3 Garniture tape drum..................................................................... 6.35
6.6.4 Garniture tape ............................................................................. 6.36
6.6.4.1 Garniture tape adjustments.................................................... 6.38
6.6.4.2 Garniture tape change .......................................................... 6.38
6.6.5 Sealing the filter rod..................................................................... 6.39
6.6.6 Automatic rod formation with sealing chamber (Cooling bar) ....... 6.40
6.6.7 Filter rod heating .......................................................................... 6.44
6.6.8 Filter rod cooling........................................................................... 6.45
6.7 Cut-off unit .......................................................................................... 6.47
6.7.1 Instruments and gauges for setting the filter way .......................... 6.48
6.7.2 Straight filter way adjustment ....................................................... 6.49
6.7.3 Ledger holder ............................................................................... 6.50
6.7.4 Installing and adjusting the ledger holder ..................................... 6.51
6.7.5 Installation of the arm ................................................................... 6.52
6.7.6 Installing and adjusting of the guide tube ..................................... 6.53
6.7.7 Installing and adjusting the diameter control nozzle ...................... 6.54
6.7.8 Adjusting the cutting ledger tubes ................................................. 6.55
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6.7.9 Adjusting the cutting ledger stroke at different filter length .......... 6.56
6.7.10 Installing the knife carrier ........................................................... 6.58
6.7.10.1 Technical maintenance of the knife holders .......................... 6.58
6.7.11 Adjusting the filter rod cutting ..................................................... 6.59
6.7.12 Adjusting the angle of the knife carrier ....................................... 6.60
6.7.13 Knife sharpening ..................................................................... 6.61
6.7.14 Automatic knife advance unit ...................................................... 6.62
6.7.15 Adjustment of the knife advancing mechanism ............................. 6.63
6.7.16 Knife sharpening ..................................................................... 6.65
6.7.17 Adjusting the sharpening disks angle........................................... 6.66
6.7.18 Knife carrier safety cover ........................................................... 6.68
6.8 Filters acceleration ............................................................................... 6.69
6.8.1 Function......................................................................................... 6.70
6.8.2 Double accelerator ....................................................................... 6.71
6.8.3 Filters transfer ............................................................................... 6.73
6.8.4 Fluted drum................................................................................... 6.74
6.8.5 Producing a filter rod for fluted drum adjustments ........................ 6.75
6.8.6 Table of parameters for setting the catching................................. 6.76
6.8.7 Transfer drum ............................................................................... 6.77
6.8.8 Output transport ........................................................................... 6.78
6.8.9 Antistatic bar ................................................................................ 6.79
6.8.10 Filter ejection .............................................................................. 6.80
6.8.10.1 Filter ejection at machine stop .............................................. 6.81
6.8.10.2 Filter ejection at bobbin splice ............................................. 6.82
6.9 Lubrication system ................................................................................ 6.83
6.9.1 Function of the lubrication system .................................................. 6.84
6.9.2 Oil change .................................................................................... 6.85
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6.9.3 Oil fill ........................................................................................... 6.85

6.10 Pneumatic system ............................................................................... 6.86
6.10.1 Description of the pneumatic systems .......................................... 6.86
6.10.2 Pneumatic group ......................................................................... 6.88
6.11 Cooling system................................................................................... 6.89
7 Maintenance ......................................................................................... 7.1
7.1 Preface .................................................................................................. 7.1
7.1.2 Chapter purpose .......................................................................... 7.1
7.2 Cleaning ................................................................................................ 7.2
7.3 Maintenance plans ................................................................................. 7.3
7.4 General point of lubrication ................................................................... 7.6
7.5 Hotmelt unit maintenance ....................................................................... 7.8
7.5.1 Washing the filter ........................................................................ 7.9
7.5.2 Replacing the filter ....................................................................... 7.9
7.5.3 Cleaning agents ..................................................................... 7.10
7.5.4 Conditional cleaning periods ...................................................... 7.10
7.5.5 Full cleaning ............................................................................... 7.11
7.5.6 Heavy deposits in the tank ......................................................... 7.15
7.5.7 Flushing the heated hoses ........................................................... 7.16
7.6 Maintenance preservation directions .................................................... 7.17
7.7 Troubleshooting .................................................................................... 7.18
8 Electrical data ........................................................................................ 8.1
8.1 Preface .................................................................................................. 8.1
8.1.2 Chapter purpose .......................................................................... 8.1
8.2 Software description .............................................................................. 8.2
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8.2.1 Description of the PLC Siemens Simatic S7-300 ............................ 8.3

8.2.2 Performing a general reset with the PG or PC (STEP 7) ............... 8.8
8.3 Access levels .......................................................................................... 8.9
8.4 Screens ................................................................................................ 8.11
9 Format change ...................................................................................... 9.1
9.1 Preface .......................................................................................... 9.1
9.1.2 Chapter purpose .......................................................................... 9.1
9.2 Changing the Inlet ledger and outlet ledger........................................... 9.2
9.3 Changing the Paper Guides ................................................................... 9.3
9.4 Changing the Counterweight .................................................................. 9.3
9.5 Changing the double acceleration rollers ............................................... 9.4
9.6 Changing the fluted drum ....................................................................... 9.5
9.7 Changing the transfer drum.................................................................... 9.7
Appendix 1 - Backup and restore ................................................................... 1.1
1.1 Preface .......................................................................................... 1.1
1.1.2 Chapter purpose .......................................................................... 1.1
1.2 Quick reference table ............................................................................ 1.2
1.3 USB drive folder structure ...................................................................... 1.3
1.4 PLC backup and restore ....................................................................... 1.4
1.4.1 Backup - Siemens S7 300 ............................................................. 1.4
1.4.1.1 Restore - Siemens S7 300................................................... 1.9
1.4.2 Backup - Siemens S7-1200 ........................................................ 1.10
1.4.2.1 Download configuration directly to the memory card ....... 1.10
1.4.2.2 Download configuration directly to a USB memory stick 1.11
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1.4.2.3 Download the configuration to a file folder of the computer

.......................................................................................................... 1.11
1.4.2.4 Restore – Siemens S7-1200.............................................. 1.12
1.4.3 Backup - Lenze 32XXC ............................................................... 1.12
1.4.3.1 Creating a backup on the Engineering PC (recommended
variant ............................................................................................... 1.12
1.4.3.2 Creating a backup on the Controller ................................ 1.13
1.4.3.3 Creating a backup using the »WebConfig« ..................... 1.14
1.4.3.4 Creating a backup with the Windows® Explorer (on the
directory/file level) ........................................................................... 1.14
1.4.3.5 Restore - Lenze 32XXC ..................................................... 1.15
1.4.4 Backup - PILZ ............................................................................. 1.18
1.4.4.1 Restore - PILZ: ................................................................. 1.19
1.5 HMI backup and restore ...................................................................... 1.20
1.5.1 Backup - Siemens KTP400 .......................................................... 1.20
1.5.1.1 Restore - Siemens KTP400 ................................................ 1.21
1.5.2 Backup - Siemens 700 Comfort .................................................. 1.22
1.5.2.1 Automatic backup ............................................................. 1.22
1.5.2.2 Backup/Restore with a memory card/USB memory stick ... 1.22
1.5.2.3 Restore - Siemens 700 Comfort ........................................ 1.26
1.5.2.4 Backup/Restore with ProSave........................................... 1.28
1.5.3 Backup – Lenze P300 ................................................................. 1.30
1.5.3.1 Restore – Lenze P300....................................................... 1.31
1.5.4 Backup - Siemens SIMATIC IPC ................................................... 1.32
1.5.4.1 Restore - Siemens SIMATIC IPC ......................................... 1.33
1.6 Drives backup and restore ................................................................... 1.34
1.6.1 Backup - Lenze 8200 ................................................................. 1.34
1.6.1.1 Restore – Lenze 8200 ...................................................... 1.35
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1.6.1.2 Restore - Lenze 9300 ....................................................... 1.37

1.6.2 Backup - Lenze 8400 ................................................................. 1.39
1.6.2.1 Restore - Lenze 8400 ....................................................... 1.39
1.6.3 Backup – Lenze 9400................................................................. 1.41
1.6.3.1 Restore – Lenze 9400 ...................................................... 1.41
1.6.4 Backup - AMK A5/A4 ................................................................ 1.42
1.6.4.1 Restore - AMK A5/A4 ...................................................... 1.46
1.6.5 Backup - KW/KWD with KW-R06 ............................................. 1.50
1.6.5.1 Restore - KW/KWD with KW-R06 ................................... 1.52
1.6.6 Backup - FESTO CMMP-AS-A5 ................................................... 1.54
1.6.6.1 Restore - FESTO CMMP-AS-A5 ......................................... 1.59
1.6.7 Backup - Siemens S120-CPU310 ....................................... 1.63
1.6.7.1 Restore - Siemens S120-CPU310 ..................................... 1.65
1.6.8 Backup - Siemens М440 ............................................................ 1.66
1.6.8.1 Restore – Siemens M440 .................................................. 1.67
1.7 Back up and Restore operations ........................................................... 1.70
1.7.1 Back-Up IPC and NI Crio Controller: .......................................... 1.70
1.7.2 Restore IPC Image ...................................................................... 1.74
1.7.3 Restore CRio files ....................................................................... 1.76
1.7.4 Backup using Clonezilla ........................................................... 1.78
1.7.5 Restore using Clonezilla ........................................................... 1.87
1.7.6 Deleting image using shell .......................................................... 1.95
1.7.7 Create Clonezilla bootable USB ................................................. 1.98
Appendix 2 - HMI and procedures ................................................................. 1.1
Main screen and Slide-in .............................................................................. 1.3
1.0/1.1 Machine information – General/Emergency line ...................... 1.4
2. Logbook – General.................................................................................. 1.5
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3. Operator setup – General ....................................................................... 1.6

3.1 Operator setup – Display settings.......................................................... 1.7
3.2 Operator setup – Bobbin change........................................................... 1.8
3.3/3.4 Process data temperature – inner/seam ......................................... 1.9
3.5 Operator setup – Gluing ..................................................................... 1.10
4. Technical setup – General ...................................................................... 1.11
4.1 Technical setup – Technical setup ......................................................... 1.13
4.1.1 Technical setup– Drive settings .......................................................... 1.14
4.1.2/4.1.3 Technical setup –Service data temperature – seam/inner ....... 1.16
4.1.4/4.1.5 Technical setup – Hot melt seam/inner .................................... 1.17
4.1.6/4.1.7 Technical setup – PVA seam/inner gluing ................................ 1.19
4.1.8 Technical setup – Diameter control .................................................... 1.21
4.1.9 Technical setup – Cleaning cycles ...................................................... 1.22
4.1.10 Technical setup – Knife control ........................................................ 1.23
4.1.11 Technical setup – Sampling ............................................................. 1.27
4.2 Technical setup – General.................................................................... 1.29
4.3 Technical setup – Start program .......................................................... 1.30
4.4 Technical setup – Stop program ........................................................... 1.31
4.5/4.6 Technical setup – Drives diagnostic ............................................... 1.32
4.7 Technical setup – Status variable ......................................................... 1.33
4.7.1/4.7.3 Status variable screens ........................................................... 1.34
4.8 Technical setup – AMK PID setup.......................................................... 1.35
4.9 Technical setup – Display settings ........................................................ 1.36
6.0 Brand Setup – General........................................................................ 1.37
6.1 Brand Setup – Admin ........................................................................... 1.38
7.0 Production – Shift log ........................................................................... 1.40
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7.1/7.2 Production – Production archive 1/2 ............................................. 1.41

7.3 Production – Shifts library .................................................................... 1.42
7.4 Production – Current shifts.................................................................... 1.43
7.5 Production – Time efficiency................................................................. 1.44
7.6 Production – Production history ............................................................ 1.45
7.7 Production – Production counter ........................................................... 1.46
8.0 User administration .............................................................................. 1.47
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D000138670
D000138670 Technical data
Rev. 02; 01.08.2018
1 Technical data ....................................................................................................1.2

1.1 Preface .........................................................................................................1.2
1.1.1 Chapter objective ................................................................................................ 1.2
1.1.2 Chapter purpose .................................................................................................. 1.2
1.2 Process description of the Rod Module ........................................................1.3
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1 Technical data
1.1 Preface
1.1.1 Chapter objective
The current chapter provides the following information:
- Operation process of the machine
1.1.2 Chapter purpose

This chapter is addressed to the:
- Operator staff
- Maintenance staff
- Service staff
- QA staff
- Management staff
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1.2 Process description of the Rod Module

The process of forming the filter rod and the filter in Rod module is shown on the diagram below:
5 Cooling unit
7 5 Tow way in
8 4
2
Format garniture 3
9
New bobbin 1
Working paper
(fig.1) Process description of the Rod Maker Module
Zone 1 – Paper supply

Zone 2 – Paper tension roller
Zone 3 – Glue application on the paper
Zone 4 – Forming the filter rod
Zone 5 – Measuring the filter rod
Zone 6 – Cutting off the filter rod
Zone 7 – Accelerating the filters
Zone 8 – Transferring the filters
Zone 9 – Output transport
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2 Safety ................................................................................................................2.2
2.1 Preface .........................................................................................................2.2
2.1.1 Chapter objective............................................................................................. 2.2
2.1.2 Chapter purpose .............................................................................................. 2.2
2.2 General Safety Information..........................................................................2.3
2.3 Safety system description ............................................................................2.4
2.3.1 Safety Sensors .................................................................................................. 2.4
2.3.2 General list of applied safety sensors ......................................................... 2.5
2.4 General Warnings for work area .................................................................2.7
2.5 Risk factors and hazards areas..................................................................2.12
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2 Safety
2.1 Preface
The current chapter provides following information:

- General safety information
- General warnings for work area
- Risk factors and hazardous areas
- Safety devices

- Operator staff
- Maintenance staff
- Service staff
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2.2 General Safety Information
The instructions and safety warnings prescribe general measures for the safeguard of worker health and
safety, such as:
- emergency procedures in the event of an accident, as well as worker evacuation in the event of fire
outbreak or serious and immediate danger;
- use of warning and safety signals;
- individual and collective protection measures;
- regular maintenance of the work environment, machinery and installations, with attention to safety
devices in conformity with the indications of the manufacturer;
- worker instruction and training.
Each operator must take care for their personal health and safety as well as that of
other people present on the work site, and a subject to the effects of their acts and
omissions, in compliance with the means received from the employer, training and
instructions.
Personnel requirements - workers must:

- make correct use of machinery, equipment, tools, hazardous substances and preparations, means of
transport and other work equipment, including safety devices;
- immediately inform the employer or supervisng personnel of any faults in devices or means available;
- not remove or modify safety, alarm or control devices without prior authorization;
- not carry out initiative operations on their own for which they are not qualified, not trained or that
may compromise personal and collective safety.
ATTENTION!
Always use gloves when operating in danger areas.
Do not wear bracelets, wristwatches, rings or necklaces that hang or hamper
operator movement. (fig.1)
(Fig.1)
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2.3 Safety system description

2.3.1 Safety Sensors
S14.2 S14.5
Fig.2 Safety sensors
Code Type Function

It locks the fluted drum rear cover. When the cover is opened the
S14.2 Safety sensor
machine is not in working condition.
It locks the safety cover of the fluted drum. When the cover is
S14.5 Safety sensor
opened the machine is not in working condition.
S14.3 S14.7 S14.4
Code Type Function

It locks the safety cover of the cut-off unit. When the cover is
S14.3 Safety sensor
It locks the safety cover of the Garniture tape Drum. When the
S14.7 Safety sensor
cover is opened the machine is not in working condition.
It monitors the garniture service tape cover. If the garniture tape
S14.4 Safety sensor
service cover is open, the machine is not in working condition.
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Safety sensors (rear of the machine)
S 16.6 S 16.5
Code Type Function

It controls the rear right door of the machine. The machine is not
S16.5 Safety sensor
in working mode when the bypass is switched off.
It controls the rear middle door of main drive. When the cover is
S16.6 Safety sensor
2.3.2 General list of applied safety sensors
No Symbol Type Function

It locks the fluted drum rear cover. When the
1. S14.2 Safety sensor cover is opened the machine is not in working
condition.
It locks the safety cover of the cut-off unit. When
2. S 14.3 Safety sensor the cover is opened the machine is not in working
condition.
It monitors the garniture service tape cover. If the
3. S 14.4 Safety sensor garniture tape service cover is open, the machine
is not in working condition.
It locks the safety cover of the fluted drum. When
4. S 14.5 Safety sensor the cover is opened the machine is not in working
condition.
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It locks the safety cover of the Garniture tape
5. S 14.7 Safety sensor Drum. When the cover is opened the machine is
not in working condition.
It controls the rear right door of the machine. The
6. S 16.5 Safety sensor machine is not in working mode when the door is
open.
It controls the rear middle door of the main drive.
7. S 16.6 Safety sensor When the cover is opened the machine is not in
working condition.
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2.4 General Warnings for work area
Thermal zones Rod module
2 1 3 4 5
Fig.5 Dangerous thermal zones on Rod module
Nr Zone Danger aspect Safety measures

1 Servo motor, Fluted Drum (thermal Skin burning (temperature around Safety cover.
zone). 100°C).
2 Servo motor, Double Accelerator Skin burning (temperature around Safety cover.
(thermal zone). 100°C).
3 Hot-melt nozzle (thermal zone). Skin burning. (temperature around Safety cover
150°C)
4 Hot-melt nozzle Douber (option) Skin burning. (temperature around Safety cover
(thermal zone). 150°C)
5 Hot-melt glue tanks (thermal zone). Skin burning (temperature around Protective coat
150°C)
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Zones with danger of mechanical injury
10
Fig.6 Areas representing threat of mechanical injury

7 Knife carrier (mechanical injury). Danger of cut off (irreversible Safety cover with protective
injuring). sensor with lock S14.3.
8 Zone of the ledger carrier Danger of cut off and Safety cover with protective
assembly (plates) (mechanical dragging (reversible injuring). sensor S16.1.
injury).
9 Garniture tape Drum (mechanical Danger of dragging. Safety covers with protective
injury). (irreversible injuring). sensor with lock S14.7.
10 Discharge Drum and Transfer Danger of dragging. Safety covers with protective
Drum (mechanical injury). (irreversible injuring). sensors with lock, respectively
S14.5
AIGER CONFIDENTIAL
D000138671
D000138671 Safety
Rev. 02, 16.10.2018
12
11
13
Fig. 7

Rear zone of the machine, Main Danger of dragging Protective door with
11
Drive (mechanical injury). (reversible injuring). protective sensor S16.6.
Rear left zone of the machine Danger of dragging Protective door with
12 (reversible injuring). protective sensor S16.7.
(mechanical injury).
Rear right zone of the machine Danger of dragging Protective door with
13
(mechanical injury). (reversible injuring). protective sensor S16.5.
AIGER CONFIDENTIAL
D000138671
D000138671 Safety
Rev. 02, 16.10.2018
Zones with danger of electric current
14
17
16
15
Fig.8 Zones with danger of electric current

Safety cover.
Danger of electric current
14 Break resistances Access is allowed to an
(irreversible injury, death)
authorized electrician ONLY.
Safety cover.
15 Transformer Access is allowed to an
Safety cover.
16 Heat exchanger Access is allowed to an
Protective door with protective
Electric cupboard in the rear of Danger of electric current sensor S16.2, S16.4
17
the machine (irreversible injury, death) Access is allowed to an
AIGER CONFIDENTIAL
D000138671
D000138671 Safety
Rev. 02, 16.10.2018
18
Fig.9 Zones with danger of electric current

Danger of electric current Safety cover.
18 Main control panel.
(irreversible injuring, death).
AIGER CONFIDENTIAL
D000138671
D000138671 Safety
Rev. 02, 16.10.2018
2.5 Risk factors and hazards areas
The RMM is designed for the manufacture of cigarette filter rods and can be used only on purpose. Changes
to the machine connected with safety devices are not permitted and could lead to an industrial accident. By
using the machine not on purpose or changing the machine, the declaration of compliance, presented by the
manufacturer, loses its value. The owner is required to keep the machine in perfect working condition. The
machine must not be altered or modified in any way.
Safety signs have been placed in machine areas where protected and residual risks could be hazardous
to the unauthorized operator:
Attention!
Zone with high danger of industrial accident occurrence.
Pass and work with great attention!
Danger of electric current!

Zone with danger of electric current
Danger of automatic start up!

Danger of automatic start up of machine or mechanism.
Danger of mechanical injury – crushing!

Zone of mechanical danger caused by the pulling or dragging action
of the working mechanisms.
Danger of burning!
Zone with danger of injury as a result of high temperature impact
Danger of flying particles!

Zone with danger of flying metal fillings or other particles.
Do not work without safety glasses.
Danger of mechanical injury – cut off!

Danger area, possible cutting off upper limbs when operating the
machine
Danger of mechanical injury – pressing and crumple!

Danger area of mechanical pressing or crumple of upper limb.
AIGER CONFIDENTIAL
D000138671
D000138671 Safety
Rev. 02, 16.10.2018
Danger of mechanical injury – pressing of leg or a hand!

Danger area of mechanical pressing or crumple of upper or lower
limb.
Danger of explosion!
Danger area, possible explosion.
Do not perform activities involving open fire or sparking!
Danger of aggressive substances!

Danger of contact substances with aggressive and corrosion properties.
You must work with appropriate and reliable personal protective
equipment!
Danger of toxic substances!

Danger of inhalation toxic vaporous and toxic substances.
Danger of welding machine!

Danger of losing sight due to welding arc. Do not look at the welding
arc.
Always wear a protective helmet!
Danger of falling objects!

Do not pass through the zone with overhead loads.
Danger from gas!

Zone with danger of natural gas leakage.
Do not start a fire or work with spark generating instruments!
Danger of strike with high tension current /over 500 V/!

Do not work without /detached/ personal protective equipment!
Danger of suspended load!

Danger of falling suspended objects.
AIGER CONFIDENTIAL
D000138671
D000138671 Safety
Rev. 02, 16.10.2018
Attention!
Hazard due to laser radiation.
Do not work without gloves preserving from mechanical injury!
Do not work without gloves preserving from chemical damage!
Do not work without special purpose boots!
Do not work without special purpose shoes!
Do not work without dust-protective mask!
Do not work without glasses!
Do not work without face mask!
Do not work with loose hair or loose clothes!
Do not work without protective shield or cover!
AIGER CONFIDENTIAL
D000138671
D000138671 Safety
Rev. 02, 16.10.2018
Do not work with unchecked ropes or with such that do not fulfill the
weight standard!
Do not work without special purpose clothing!
Do not work without welding helmet!
Specialized personnel ONLY!
Specialized electrician ONLY!
All persons must stay clear of hazard areas while the machine is operating. Maintenance technicians may
approach or enter the machine only after having put the machine in maintenance status (see chap.
Maintenance). The machine must be regularly maintained according to the Operation manual instructions.
The condition of safety devices must be checked periodically. Every lapse in the maintenance can result in
an industrial failure and accident.
It is not permitted untrained and unqualified personnel to work with the machine.
Everyone working with the machine must be informed and introduced to this
instruction.
AIGER CONFIDENTIAL
D000138671
D000138671 Safety
Rev. 02, 16.10.2018
Explanatory note:
The warning signs are triangles upon which in yellow background with black graphic
the possible danger is illustrated conventionally
The indexing signs are rectangular or square, upon which in blue background the
information, which the machine operator must receive is illustrated conventionally.
The obligatory signs are round, upon which in blue background is illustrated the
condition, which the operator must follow during work with the machine.
The prohibiting signs are round with red border, upon which in white background the
action, which is disallowed to carry out, is illustrated conventionally.
AIGER CONFIDENTIAL
D000138671
D000138671 Safety
Rev. 02, 16.10.2018
Machine safety depends on the respect of the schedule and modalities of periodic checking, maintenance,
cleaning and the replacement of used parts.
The work area:

- must always be clear of boxes, tools and other objects that could hamper movement or fall, and
nothing must interfere with the freedom of movement of machine operators;
- access to the work area of persons not directly involved in machine operation and/or maintenance is
strictly prohibited;
- must be sufficiently illuminated, without shadows or bright reflected light which could create further
operating risks;
- must be kept clean to prevent the floor surface from becoming slippery and creating a hazard risk.
Particular attention is drawn to the following general rules:

- keep unauthorized persons clear of the work area;
- wear personal safety equipment;
- do not use the machine or guards as work benches;
- do not introduce hands, arms or any part of the body when the machine is operating;
- after completing a work cycle the machine must remain in good working condition, at the start of
another working cycle all safety devices must also be checked;
- the condition of safety devices must be checked periodically; every lapse in the maintenance can lead
to an industrial breakdown and accident.
Precautions
The precautions protect the operating and maintaining personnel from the machine’s dangerous components.
The protective precautions include all of the safety covers, doors and safety sensors. Before running the
machine, all covers and doors must be closed.
Precautions through safety sensors with locking mechanism
The safety covers of the knife carrier, discharge, transfer drum and Garniture tape drum are equipped with
safety sensors with locking mechanism.
Safety sensors
All the safety covers and doors are observed by safety sensors. When a safety cover is open, it causes an
immediate stop of the machine.
EMERGENCY STOP button
The buttons for emergency stop immediately terminate the work of the machine. It is intended to be used in
case of failure or if there is a direct threat for the operating or maintenance personnel.
ATTENTION!
In case of danger for people or machine, activate the EMERGENCY STOP!
AIGER CONFIDENTIAL
D000138671
D000138671 Safety
Rev. 02, 16.10.2018
The emergency stop loop is discontinued in the following cases:
- Pressed emergency stop button regardless of the machine in the production line on which it was
activated;
- Open protective cover of the machine to which said cover belongs;
- Open contact of the relay monitoring non-symmetric voltage of the power supply grid, availability of
phases and phase order sine wave.
ATTENTION!
Conductors in orange colour can be under residual voltage even after the emergency
stop has been activated. That is why any interference in the electrical cabinets is to be
carried out by authorized staff only.
ATTENTION!
After switching off the power supply to the electrical boards, wait for 5 seconds before
opening them.
Detection loop (Monitoring Loop)
The monitoring loop includes all machines in the production line. Whenever it is discontinued a fast stop of
the machine is activated.
The monitoring loop is discontinued in the following cases:
 failure in the inverter module.

 failure in the system that hands over the plasticizer.
 insufficient air pressure fed from the supplying compressor.
 failure on the main motor.
 insufficient oil pressure.
 lack of synchronizing impulses from built-in sin-cos Encoder in the main electric motor.
AIGER CONFIDENTIAL
D000135552
D000135552 Transport and installation
Rev. 03; 26.07.2018
3 Transport and installation ......................................................................... 3.2

3.1 Preface ................................................................................................... 3.2
3.1.1 Chapter objective ..................................................................................... 3.2
3.1.2 Chapter purpose ....................................................................................... 3.2
3.2 Unloading of machines ......................................................................... 3.3
3.2.1 Removing of securing elements from pallets ........................................ 3.3
3.2.2 Unloading pallets from the transport vehicle ....................................... 3.5
3.3 Unpacking the machine ......................................................................... 3.7
3.3.1 Opening of wooden boxes/pallets ....................................................... 3.7
3.3.2 Removing aluminium thermo-foil ............................................................. 3.7
3.3.3 Removing stretch and bubble foil .......................................................... 3.9
pallets ................................................................................................................... 3.10
3.3.5 Taking the machines off the pallets ..................................................... 3.10
3.3.6 Disposal or storage of packing ............................................................ 3.11
3.4 Installation of the machines ................................................................ 3.12
AIGER CONFIDENTIAL
D000135552
Rev. 03; 26.07.2018
3 Transport and installation
3.1 Preface
- Transportation and unpacking of the machine
- Maintenance staff
- Service staff
The illustrations in this chapter are exemplary and do not necesserily depict
the actual machine.
AIGER CONFIDENTIAL
D000135552
Rev. 03; 26.07.2018
3.2 Unloading of machines

3.2.1 Removing of securing elements from pallets
The machine packing (fig.1) is in consideration with the transportation mode and the extent of the
hazardous conditions influencing the machine. The machine is delivered to the customer wrapped up in
aluminum foil (pos.2) firmly set onto a wooden pallet (pos.1).
(fig.1)
Materials used for securing machines/products during transportation are passive materials only - for
protection against mechanical damage; they are selected with consideration to the arranged type of
transport:
- Airbags
- Securing straps
- Supporting beams
- Additional wooden pallets
Securing straps and Airbags Securing straps, Airbags and Securing straps, Supporting
Supporting beams beams and additional
wooden pallet
ATTENTION! During all operations, operatives must wear suitable

protection including helmets, gloves, safety shoes, safety overall, and any
other items required by applicable legislation.
AIGER CONFIDENTIAL
D000135552
Rev. 03; 26.07.2018
Removing of securing straps (fig. 2):
After opening the truck’s trailer all securing straps should be removed. To remove the straps, unlock and
loosen them with the ratchet handle (shown on fig. 2).
Metal ratchet handle
Securing straps
(fig.2)
Removing airbags, supporting beams and additional wooden pallet (fig. 3):
After removing the securing straps, the next materials to be removed are the airbags, the supporting
beams and the additional wooden pallet used for extra securing/fixing of pallets during transportation.
Supporting beams could be fixed to the trailer’s bottom with screws and/or nails, which should be
removed before removing beams.
Additional wooden pallet was fitted with the securing straps and after removing the straps it can be
removed as well.
Before removing the airbags they should be deflated pushing down the button (shown on fig. 3), which
opens a valve, allowing the airbag to be pulled out and rolled up. When reusing the airbags it is very
important to close the valve after deflating, so that the valve is protected against damage or dirt.
AIGER CONFIDENTIAL
D000135552
Rev. 03; 26.07.2018
Additional wooden pallet
Supporting beam
Valve Pushbutton
(fig.3)
3.2.2 Unloading pallets from the transport vehicle

After removing all elements securing the pallets to transport vehicle, the pallets are ready to be
unloaded.
Follow all labeling and instructions on the packing case.
Equipment used for handling/unloading pallets must be suitable lifting – shape and size, mass (weight)
and lifting points. Make sure that all personnel are adequately trained and always appoint a person
responsible for controlling the lifting equipment.
Heavy machinery parts can be transported (loading, unloading) using

lifting equipment. The kinetic energy of the moving parts of the machinery
due to handling during transportation can pose hazards to people nearby.
AIGER CONFIDENTIAL
D000135552
Rev. 03; 26.07.2018
When lifting pallets with a forklift, follow the marks on the pallets shown on the table below and fig. 4.
Mass center for the machine and the pallet
Place for putting the fork for lifting
Position
of forks
Mass center for the machine

and the pallet
Labels with gross weight

and contain of pallets
(fig.4)
Take care not to cause damage to machines when inserting the forks under the
pallets.
Transport the pallets close to the installation site. Make sure there is enough free space around the
machine for forklift maneuvers.
AIGER CONFIDENTIAL
D000135552
Rev. 03; 26.07.2018
3.3 Unpacking the machine
The materials used for packaging are stretch foil, bubble-air foil, anti-corrosive liquids, packing paper,
wooden pallets/boxes, cardboard boxes and envelopes, transport cases, humidity indicators, aluminum
thermo-foil.
3.3.1 Opening of wooden boxes/pallets

Before opening the wooden boxes, remove nylon cover from the top of the pallet.
All side covers and top cover are fitted together with screws (fig. 5).
Nylon cover
Screws
(fig.5)
3.3.2 Removing aluminium thermo-foil

After opening wooden box/pallet leave the machine with the aluminum thermo-foil wrapping for 24
hours so that no condensation occurs on the metal surfaces, which might cause corrosion. The ambient
temperature must be between +15 °С and +35 °С. The packing-case can be exposed to a higher
temperature (up to +40 °С) for not longer than 24 hours. Follow all labeling and instructions on the
packing case. The minimum requirement for all electrical equipment is correct operation between
temperatures of +5 °С to +40 °С.
Before removing the foil, check its condition and the humidity indicator placed on it. Follow its indications
(fig. 6):
 30% blue – the atmosphere underneath the foil is dry;
 40% pink – you must check the integrity of the protective foil;
 50% pink – you must change the packing if you intend to store the machine;
 70% pink – the atmosphere underneath the protective foil is humid (check the integrity of the
protective foil for breaches). The machine must be dried before you connect the power supply.
AIGER CONFIDENTIAL
D000135552
Rev. 03; 26.07.2018
OK
DANGER
(fig.6)
Remove the aluminum foil.
Take care not to cause damage to machines when removing aluminium foil.
(fig.7)
AIGER CONFIDENTIAL
D000135552
Rev. 03; 26.07.2018
3.3.3 Removing stretch and bubble foil
Proceed with control checking for completeness and eventual damages due to transportation.
Remove stretch and bubble foil (fig. 8).
Take care not to cause damage to machines when removing stretch and
bubble foil.
(fig.8)
AIGER CONFIDENTIAL
D000135552
Rev. 03; 26.07.2018
pallets
To take the machines off the wooden boxes all fixing consoles and securing straps must be removed first
(fig.9).
Loosen the transport screws (pos.1) and their nuts (pos.2) on both sides of the machine;
Remove screws (pos.3) and the fixing consoles (pos.4). Remove securing straps (pos.5).
1 2
3 4
(fig.9)
3.3.5 Taking the machines off the pallets

To take the machines off the wooden boxes/pallets, first they should be lifted up with hydraulic jack
(fig.10). The hydraulic jack must be positioned in the same spot as the fixing consoles. The machine must
be lifted high enough from the pallet, so they could be picked up with a forklift truck.
The hydraulic jack you use must comply with assumed loads and be
regularly inspected in accordance with the applicable regulations.
.
After lifting the machines with hydraulic jack, put securing beams underneath.
Pick up the machine with forklift truck. Before lowering the machines on the floor fit/put the supporting
legs on the machine.
AIGER CONFIDENTIAL
D000135552
Rev. 03; 26.07.2018
Hydraulic jack
Position for the hydraulic

jack
Type 1 Type 2
(fig.10)
Transport the machines close to the installation site. Make sure there is enough free space around the
machines for forklift maneuvers.
Machinery and parts which cannot be transported manually are equipped with appropriate instruments
for hoisting or enable the connection of these instruments. These instruments could be e.g. eye bolts, hooks
for lifting devices or suitable mounting holes for lifting devices, etc.
Also ensure that:
- Machine elements are secured against movement during transport.
- Parts that could become loose while the machine is being transported are properly secured.
3.3.6 Disposal or storage of packing

Once the machine has been removed from the pallet, separate the packing material according to type
to facilitate disposal or storage. If packing is to be disposed of, this must be done in compliance with the
legislation.
AIGER CONFIDENTIAL
D000135552
Rev. 03; 26.07.2018
3.4 Installation of the machines
The installation area must be large enough to house the machine. Before positioning the machine, make
sure that the electrical and compressed air supplies have been laid on at suitable position.
Electrical lines must comply with the legislation applicable in the country of installation, and in particular
must:
- be made using cables of cross section adequate for the installed power of the machine and the
length of the connection;
- be adequately grounded;
- be equipped with adequate disconnecting and automatic protection devices, differential earth
(ground) switches, and short circuit protection.
The initial installation must be carried out by authorized personnel of Aiger

Engineering Ltd. Otherwise Aiger Engineering Ltd. bares no responsibility for
damages during unpacking or installation of the machine.
Make sure that the voltage of the factory’s power supply corresponds with
that given in the technical specifications. See diagrams and instructions in
Circuit documentation.
Before linking the machine to power supply, make sure of the principle scheme in Electrical
documentation. Connection between machines ensures electrical connections of Emergency system, speed
control signals and start-stop signals. After linking the machine to main supply and to upstream machine,
it is mandatory to make complete exam of rotation sense of all motor reducers and to change the sense
(if necessary) by changing the supply wires of respective reducer. For starting motor it is absolutely
necessary to link up all machines in line.
Only qualified specialized technicians should perform the installation of the machine.
Contact Aiger Engineering Ltd. for assistance.
Tel.: +359 32 905 000
Fax: +359 32 947 000
e-mail: support@aiger.com
AIGER CONFIDENTIAL
D000138673
D000138673 Running the machine
Rev. 02; 31.07.2018
4 Running the machine .........................................................................................4.2

4.1 Preface .........................................................................................................4.2
4.1.2 Chapter purpose .................................................................................................. 4.2
4.2 Starting the machine ....................................................................................4.3
4.3 Normal and Emergency stoppages ..............................................................4.5
AIGER CONFIDENTIAL
D000138673
Rev. 02; 31.07.2018
4 Running the machine

4.1 Preface
- Starting procedure
- Normal and emergency stoppages

- Operator staff
- Service staff
AIGER CONFIDENTIAL
D000138673
Rev. 02; 31.07.2018
4.2 Starting the machine

Before starting the machine, make sure that there is a good supply of materials, as well as sufficient vacuum.
Check whether the machine is properly adjusted for operation. Then:
- carry out all the required start up procedures of the machine;
- prepare the rest of the machines in the line if any;
- check the actuated “Emergency stop”, reset if any;
- if the machine has stopped because of an error or emergency situation reset through the “Reset” button.
Sequence of steps needed for the daily start of the machine:
 Close the doors of all electric cabinets and remove all unnecessary objects from them;
 Load the machine with all the needed materials – filter material, glue and plasticizer;
 Switch on the compressor that centrally supplies air to the whole machine;
 Make sure all power supply switches of the modules connected in line are turned ON.*
 Switch /connect the machine to the power supply from the main switch;
 Check for pressed emergency buttons. If there are pressed - release them;
 Switch on the cooling module of the machine;
 Check the current state of the machine knives. Replace them with new ones if needed;
 Switch on all heaters of the machine;
 Wait for the right working temperatures to be reached;
 Switch on all secondary drives;
 Switch on the main drive of the machine.
Procedure for switching the machine into production mode:
 Check the settings of all the needed production parameters, displayed on the main display of the Rod
Maker Module and adjust them if necessary.
 Wait for the right production temperature of all thermal zones to be reached. Current temperatures are
displayed on the main display.
 Test the supply of hot-melt glue. If all the systems function normally then switch to automatic mode.
 Switch on and test the cold glue system from the main display.
 Stretch the garniture tape.
 Load paper and filter material.
 Start all secondary drives.
 Adjust all production materials (paper, filter material) to the initial production stage, using inch mode of
machine.
*When the machines are connected in line their power supply is received from the Rod Maker Module (RMM)
– main switch ON. However, if they have individual main switches connecting/disconnecting them from the
common power supply (such is the case with Object Insertion Module (OIM)) – ALWAYS ensure their main
switch is ON when starting the line. Otherwise the Virtual Master Controller regulating the drives of the
machines will not be able to start, and consequently the FLeX line will not be able to start.
If you encounter such situation, turn OFF the main switch -> turn ON the power supply switches of the modules
-> turn back ON the main switch.
AIGER CONFIDENTIAL
D000138673
Rev. 02; 31.07.2018
Manual or automatic start of the machine
Rod Maker Module can be started in manual or automatic mode of production.
B80.1
(fig.1)
Main operation panel*
Start in automatic mode
After switching on the main drive of the machine from B80.1 (green button) on the main operation panel
(location illustrated on the fig. 1), you must commence the following starting sequence:
 Start the supply of heated glue;
 Start the spraying of the plasticizer;
 Cut of the filter rod by the rod severer;
 Discard (reject) predetermined number of produced filters;
 Accelerate the main drive to the set from the HMI display production speed.
Start in manual mode
In manual mode (the mode can be set from the HMI display), located on the main control display of the
machine. Switching on the main drive (B80.1 green button), you must commence the following starting
sequence:
 Start the supply of heated glue
 Start the spraying of the plasticizer
 Cut of the filter rod by the rod severer
 Discard (reject) predetermined number of produced filters
*For detailed information on the main operation panel, please refer to chapter “5.Control Panels”.
AIGER CONFIDENTIAL
D000138673
Rev. 02; 31.07.2018
4.3 Normal and Emergency stoppages
Machine can be set stationary mode (inactive state) in three ways:
- Programmed stop;
- Emergency stop
Programmed stop
The programmed stop (fig.2) is a procedure for the normal stop of machine. To execute programmed stop
you must commence the following sequence:
 Press B80.1 button. Programmed stop procedure is started;
 Press faceplate button. All secondary systems and drives are switched off;
 Switch off all heating points from faceplate button (if necessary);
 Clean up all the remaining filters and filter material;
 Cut off the power supply by turning switch SH2.1 (red handle);
Switch off the compressor that supplies air to the whole machine.
SH2.1 B80.1
(fig.2)
Buttons used for programmed stop
AIGER CONFIDENTIAL
D000138673
Rev. 02; 31.07.2018
Emergency stop
B10.1
(fig.3)
Emergency stop buttons
Machine emergency stop is carried out by pressing the emergency button B10.1 located on Rod maker
module. Pressing this button is meant only in cases when there is direct danger for the operator or the
maintenance personnel, as well as in case when there is danger of breakdowns in the machine.
An “Emergency stop” immediately stops all machine movements. The button is

used to stop the machine only if it necessary or in emergency situations.
Test mode of production without materials
B80.1 USB
B80.2
(fig.4)
To set the machine in test mode of production without materials you must commence the following sequence:
 Start the main drive by pressing B80.1 button;
 Machine can be turned back to inactive state by pressing button B80.2.
 The USB of machine is connecting the touch display for data transfer.
AIGER CONFIDENTIAL
D000138673
Rev. 02; 31.07.2018
Start of the machine after servicing a breakdown
To start the machine after servicing a breakdown during production you must commence the following
sequence:
 Remove all filters and filter materials from the following zones of the machine:
 Diameter control system;
 Rod severer;
 Modules that transport filters ant filter materials;
 Service the breakdown;
 Close all error messages on the main display;
 Release all activated emergency buttons;
 Start all secondary drives.
At the end of work, carry out the following procedures:
- stop the machine normally;
- switch off the machine electric supply;
- switch off pressure air supply;
- clean the machine.
AIGER CONFIDENTIAL
D000138674
D000138674 Control panels
Rev. 05; 09.05.2018
5 Control panels .......................................................................................... 5.2

Preface ................................................................................................ 5.2
5.1.1 Chapter objective ..................................................................................5.2
5.1.2 Chapter purpose ....................................................................................5.2
RMM control panels description ......................................................... 5.3
5.2.1 Main control panel .................................................................................5.3
5.2.2 Additional control panel .......................................................................5.4
5.2.3 Sampling control panel .........................................................................5.5
Traffic light ......................................................................................... 5.6
Main switch of the line ....................................................................... 5.7
Rod module pneumatic system .......................................................... 5.8
Driving system ................................................................................... 5.9
Main drive motor .............................................................................. 5.11
Warning sensors and other type of sensors ..................................... 5.12
Sikora measuring head .................................................................... 5.17
5.9.1 Diameter measuring principle ........................................................... 5.17
5.9.2 Installation ............................................................................................ 5.18
5.9.3 Device Calibration .............................................................................. 5.18
5.9.4 SIKORA measuring device maintenance ......................................... 5.19
5.9.5 Cleaning the CCD-sensor-line ........................................................... 5.19
Temperature sensors and heaters. ................................................... 5.20
Motors............................................................................................... 5.21
Fans .................................................................................................. 5.23
Executive mechanism ....................................................................... 5.24
General list of applied sensors ........................................................ 5.27
Operating messages ........................................................................ 5.29
AIGER CONFIDENTIAL
D000138674
Rev. 05; 09.05.2018
5 Control panels
Preface
- Operation panel controls
- Faceplate buttons
- Operating messages

- Operator staff
- Service staff
Note: This chapter provides information on the control panels of the machine, their buttons, switches
and functionality. The location of Main operation panel (1), Additional operation panel (2) and
Sampling control panel (3) is illustrated below:
3 1
(Fig. 1)
AIGER CONFIDENTIAL
D000138674
Rev. 05; 09.05.2018
RMM control panels description

5.2.1 Main control panel
The Rod Module Main operation panel is shown in (fig.2). The code and function of all buttons and
displaying elements are described in the following table.
(Fig. 2) Rod module main control panel

Code/Icon Type Function
Mechanical Holder It facilitates the positioning of the main control panel.
B80.2
Two hands button – press and hold the button while turning
Black button
B80.3.
B80.1
Green button Start of main drive.
B80.2
Red button Quick stop of main drive.
USB
USB slot A slot for USB drive on the control panel for data transfer.
B80.3
Switch Raises or lowers the cooling chamber accordingly.
B10.1
Switch – Emergency stop It triggers a line stop. To be used in cases of emergency.
U92.4
Main display – indication and settings of all parameters of the
Display
machine.
AIGER CONFIDENTIAL
D000138674
Rev. 05; 09.05.2018
5.2.2 Additional control panel
(fig.3) Format garniture control panel

81.1
Button (blue) Reset button.
81.2 It controls the hot-melt glue mode. Left

position – test supply of glue, middle
Switch (black) position – automatic mode, right
position – turns on glue supply
manually.
81.3 Open/close the knife head cover.
Switch Works in conjunction with the pressed
(Three-positioned, non-
STOP button (on the support control
self-locking.)
panel).
B81.4
Initial suction of tow by the transport jet
Button (black)
(during machine standstill).
B81.5
Button (black) Inch mode – main drive.
AIGER CONFIDENTIAL
D000138674
Rev. 05; 09.05.2018
5.2.3 Sampling control panel

B10.2
Emergency stop It triggers a line stop. To be used in cases of emergency.
B58.4
Button with light It makes a series of dry filters. The number can be set through
indication (green) display U92.4.
B58.6
Button with light It makes a small probe of wet filters, for example 20. The
indication (green) number can be set through display U92.4.
B58.5
Button with light It makes a large probe of wet filters – 100 filters. The number
indication (green) can be set through display U92.4.
AIGER CONFIDENTIAL
D000138674
Rev. 05; 09.05.2018
Traffic light
The traffic light on the machine is used to indicate different states and operation modes during production.
Please refer to tables below to find information about the different indications and the description of the
events of which the operator is informed.
Indication Description
Buzzer Continuous light
RUN MODE of the machine
Green lamp During START/STOP PROCEDURE

Pulse light Stand-by Mode working in line
During GO TO POSITION PROCEDURE
HMI LAMP TEST button is pressed
Continuous light
SYSTEM WARNING
Yellow lamp
Pulse light MATERIALS WARNING
Constant light
ERROR
Red lamp
Pulse light
Pulse sound MATERIALS WARNING
Buzzer HMI LAMP TEST button is pressed
Detailed description of the different modes and events is outlined in the table below:
Event Description
RUN MODE Operation mode of the machine at working speed.
START PROCEDURE Starting mode of the machine. From the moment of start until the end
of the Start Procedure, as set in the HMI.
Refer to Appendix 2 – HMI and procedures for information on Start
Procedure.
GO TO POSITION PROCEDURE Drive positioning mode of the machine.
STOP PROCEDURE Stopping mode of the machine. From the moment of pressing stop,
error or other event that stops the machine regularly (while machine
is in operation) until the end of the Stop Procedure, as set in the HMI.
Refer to Appendix 2 – HMI and procedures for information on Stop
Procedure.
SYSTEM WARNING System Warning – Occurs in special operation modes: Without
Materials, Cleaning, Working in Stand Alone mode of the module.
MATERIALS WARNING Low material warning – Occurs when there is plug wrap on bobbin
is running out, low triacetine level, low supply of filter rods, low
temperature, bobbin change, plug wrap splicing, dry or wet
sampling.
ERROR Error is raised (regardless of error type).
LAMP TEST Testing mode for all indications on the light column – light and sound.
Test is performed by pressing Lamp Test button on the HMI slide-in
-> .
Refer to Appendix 2 – HMI and procedures for information on Slide
in pane of the HMI.
AIGER CONFIDENTIAL
D000138674
Rev. 05; 09.05.2018
Main switch of the line
The main switch of the machine, includes the working hours counter and the switch that bypass the
safety sensors of the electrical cabinet doors (fig.4).
SH2.1
S16.1 U12.6
(fig.4) Main switch and working hours counter
Code Type Function

SH2.1 Main switch Switch on the machine to the power supply.
U12.6 Counter Monitors the temperature in the electrical cabinet
Allows work when the protective covers are not closed (for
S16.1 Switch with a key
maintenance purposes). Only for the electrical cabinet doors.
AIGER CONFIDENTIAL
D000138674
Rev. 05; 09.05.2018
Rod module pneumatic system
2 1 4 3
5 7
(fig.5) Rod module pneumatic system
№ Type Function
1 Pressure gauge Displays (measures) pressure at the entrance of the pneumatic system.
2 Reduction valve Controls (sets) pressure at the entrance of the pneumatic system.
3 Pressure gauge Displays (measures) pressure of diameter control system
4 Reduction valve Controls (sets) pressure of diameter control system
5 Reduction valve Controls (sets) pressure to the fluted drum.
6 Pressure gauge Measures pressure supplied to fluted drum.
7 Reduction valve Controls (sets) pressure to the garniture tape.
8 Pressure gauge Measures pressure supplied to the garniture tape.
AIGER CONFIDENTIAL
D000138674
Rev. 05; 09.05.2018
Driving system
The system for drives control in AIGER PRIME RMS machine is located in the control cabinets shown
on (fig.6).
PLC-CAM controller
(fig.6)
Rotation speed
The main drive rotation speed can be set trough:
- Potentiometer RT71.5 (AIGER PRIME RMM control panel) in trigger speed;
- Main display U92.4 on the AIGER PRIME RMM machine in automatic mode of production.
In automatic mode of production, the following speeds can be set through display U92.4:
- Speed of the drive at start (trigger speed);
- Speed of the drive at jog mode (jogging speed);
- Working (production) speed;
- Speed of the drive at conglomeration (attachment) mode.
Controlled (Slave) drives
All the controlled (Slave) drives are rotating in synchrony with the main drive. The speed of each
one of them can be set individually while sustaining (setting) predetermined correlation between the
speed of the main drive and the speeds of the slave drives.
- Delivery roller motor – M110.5;
AIGER CONFIDENTIAL
D000138674
Rev. 05; 09.05.2018
- Stretch roller motor – M108.5;

- Stretch roller motor – М106.5;
- Plasticizer pump motor – М104.5;
- Motor driving the garniture tape drum – М22.5;
- Tension roller driving motor – М24.5;
- Double accelerator motor – M28.5;
- Fluted drum motor – M29.5;
- PVA glue;
- Hot melt glue pump – M32.3
Counting the filter cuts and generating filters counting impulse sequence
A controller, located on the main drive, brings the signal to PLC-CAM controller which generates a
single impulse for each revolution of the main drive. PLC-CAM controller counts filter cuts.
Inverter modules
Element Machine Inverter Control Code Sensor EMC-Filter

Main drive RMM U20.5 Servo M20.5 Encoder -
Tension roller RMM U24.5 Servo M24.5 Resolver -
Fan – Fluted Drum
RMM U26.5 Vector M26.5 - -
Blower
Double accelerator RMM U28.5 Servo M28.5 Resolver -
Fluted drum RMM U29.5 Servo M29.5 Resolver -
Hot-melt glue pump RMM U32.5 Vector M32.3 - -

Bobbin accelerator RMM U30.5 Vector M30.5 - -
Garniture tape drum RPM U22.5 Servo M22.5 Encoder -
Stepper motor drives
Element Machine Drive Control Code

AIGER FM
PVA inner glue U33.2 Stepper motor M33.3
PRIME
PVA seam glue AIGER FM
U33.5 Stepper motor M33.6
(option) PRIME
AIGER CONFIDENTIAL
D000138674
Rev. 05; 09.05.2018
Main drive motor
М20.5
(fig.7)
Air pressure settings for ejecting the filters out of the fluted drum
(fig.8) Air pressure settings
The air pressure settings to the fluted drum should vary from 3 to 4 bar. The default setting is 3
bars. Air pressure in the range of 3.5 - 4 bars is used in the production of heavy filters (length
greater than 126mm).
Air pressure settings check is carried out by producing a test sequence of filters. To perform the
check, do the following:
 Set the required number of wet samples on the main display U92.4.
 Press the wet samples start button (B58.6 button on the control panel for wet and dry samples series)
while the machine is in production mode.
 If the air pressure settings are correct and functional, the number of cast away filters should be
equal to the predetermined number of wet samples.
In case of inadequacy at the last step the air pressure to the fluted drum should be adjusted.
AIGER CONFIDENTIAL
D000138674
Rev. 05; 09.05.2018
Warning sensors and other type of sensors
S 12.2
S 29.1
S58.3
(fig.9) Warning sensors and other types of sensors
Code Type Function

Control of the filter rod cutting. When closing the cover of the
S 12.2 Magnetic sensor
rod severer the filter rod is cut.
S 29.1 Inductive sensor It synchronize fluted drum and knife head.
Photo electric It controls the safety cover of the ledger carrier lamellas. When
S 58.3
proximity the cover is opened the machine is not in working condition.
It monitors the machine output. When it is overloaded the machine
S 72.4 Inductive sensor
is not in working condition.
AIGER CONFIDENTIAL
D000138674
Rev. 05; 09.05.2018
Warning sensors and other type of sensors

S 58.2 U6.6 S 58.5
S 72.6 S8.1 S8.2
Code Type Function

Dynamic control of the filter rods: control of the cut filter
S58.2 Optic sensor
rods on higher and lower level.
S58.5 Optic sensor It creates information for the output production.
U6.6
Antistatic It removes the statistic charge accumulated in the filter rod.
(option)
S8.1
Inductive sensor Control of the standstill condition of the machine.
S8.2
Control of the oil pressure, when the pressure is under 0, 6
S72.6 Pressure sensor
bars it submits a signal for machine operation stopping.
AIGER CONFIDENTIAL
D000138674
Rev. 05; 09.05.2018
Warning sensors and other types of sensors
S 24.8 S 76.1
S 76.7 S 76.3 S 76.5
Code Type Function

It allows the glue process, when the holder of the splicing band is
S76.1 Inductive sensor turned into working position. In fulfilling the process of splicing
when the holder is not in working position: the machine stops.
It controls the position of the bobbin changer after turning: it stops
S76.3 Inductive sensor the motor and gives a signal for fixation from the locking
mechanism.
It allows the bobbin changer glue process, when the used bobbin
S76.5 Optic sensor
paper reaches the assigned minimal diameter (right position).
It starts the bobbin changer turning, when the used bobbin paper
S76.7 Optic sensor
reaches the assigned minimal diameter (left position).
It controls the drawing out of the paper. It regulates the speed of
S24.8 Encoder
the tension roller.
AIGER CONFIDENTIAL
D000138674
Rev. 05; 09.05.2018
S76.8 Rear side
Code Type Function

Magnetic sensor It monitors the position of the cylinder piston, which activates the
S76.8
/reed/ locking pin.
AIGER CONFIDENTIAL
D000138674
Rev. 05; 09.05.2018
S 78.1
S 76.4
Rear side
Code Type Function

Control over the pressure of the compressed air for the machine
S 78.1 Pressure sensor supply. In entry pressure under 4 bar the machine stops and it
brings an error message.
Control over the pressure of the compressed air for the supply of
S 76.4 Pressure sensor the transport nozzle. In entry pressure under 3 bar the machine
stops and it brings an error message.
AIGER CONFIDENTIAL
D000138674
Rev. 05; 09.05.2018
Sikora measuring head

Sikora measuring head is a measuring system to control the rod diameter in production.
The measuring values are collected contact-free, by highlighting with a laser diode and saving the
emerging picture information with a light-sensitive sensor line. An integrated signal processor evaluates
the measured data.
In addition Sikora 2010 XY measuring head has only one operating mode and nothing to switch.
Fig. 14 Sikora measuring head
5.9.1 Diameter measuring principle
The measuring device works with the shadow projection method. The measuring object will be highlighted
in all existing axes with monochromatic light emitted by a laser diode. The resulting shadow is registered
at a sensor line. An internal signal processor evaluates the shadow information and calculates the
measuring object diameter.
Fig. 15 Geometry of a two-axes measuring head for diameter measuring evaluation
AIGER CONFIDENTIAL
D000138674
Rev. 05; 09.05.2018
The two-axes measuring gauges determine diameter values for two 90° adverse displaced measuring
axes. With the positions of the local maximum/minimum intensity values inside the accompanying
diffraction, the measuring object diameter could be accurate determined.
5.9.2 Installation
The measuring device can be installed at any position of the line. Make sure to keep the measuring object
dry, as water drops may cause error messages.
When installing the measuring head the direction of production flow has to be taken into account in order
to keep any production contaminants from getting into the measuring head.
Mount the measuring head and move it to the measuring position, watch out for correct positioning of the
measuring opening by checking the respective marks on the device housing. The centre of the measuring
object should be located at the intersection of these marks.
5.9.3 Device Calibration

To switch on the Sikora device make sure that the measurement openings are free from dirt and supply
the device with the specified voltage. In order to switch it off disconnect the device from the power line
by pulling the main supply connector. The denoted measurement accuracy will be reached in about 3
minutes after switching the device on.
Do not touch the light source and sensors with your fingers (fouling the
measuring openings!) or with metal objects (scratches!).
Danger warning through laser beam.

The device works with an infrared laser diode. Be aware that these
laser beams are invisible for human eyes! Avoid looking into the light
source.
The measuring devices have on the light source side a three-colored diode to show the device status (see
the table below).
Diod light color Device status

Green light Measuring value is valid
Red light Camera fault
Yellow - flashing: When device is switching on
Degree of fouling over configured threshold

Green- flashing
(typ. 30%)
Missing connection to REMOTE

Red-green - flashing:
If REMOTE is not connected but telegram “Internal” activated, the LED wills
continuous flash red-green. It has no influence to measuring operation!
AIGER CONFIDENTIAL
D000138674
Rev. 05; 09.05.2018
5.9.4 SIKORA measuring device maintenance

The measuring device itself needs no maintenance. To clean the frame, do not use any aggressive cleaner.
It is recommended to take care that the openings for the light are kept clean and free of any kind of
dirt. Check them regularly.
If necessary to clean the measurement openings follow the procedure described below:
- Remove the measuring object from the measuring head;
- Open measuring head frame – remove the cover plate at the front by unfastening the knurled
screws or removing the rubber plate;
- Clean measuring head – wipe the filter screen from the sensor line, the laser diode and the
measuring openings with the cleansing tissue;
- Close measuring head frame.
5.9.5 Cleaning the CCD-sensor-line
In case of encumbered environmental condition in the zone of installation of the measuring head, a
compressed-air rinsing is recommended. If strong fouling exists, first clean the CCD-lines with the
accordant commercial industrial alcohol.
Industrial-alcohol is an aggressive detergent and will leave a grease-film

on the CCD-Lines when you’re using it.
To clean the CCD-lines from all residues, re-treat them with a commercial, effective glasses cleaner
(covered with cleanser) after first cleaning.
Use a pin gauge to check out the measuring accuracy of a measuring

system. The determined measuring value should be equal to the
measuring value from the delivered certification within denoted
tolerances.
For more information please visit www.sikora.net.
AIGER CONFIDENTIAL
D000138674
Rev. 05; 09.05.2018
Temperature sensors and heaters.
U6.8
S91.2
S91.4
Fig.16 Temperature sensors
Code Type Function

It follows the temperature of the cooler for the filter rod
S91.2 Temperature sensor
formation.
It follows the temperature of the bed cooling for the
S91.4 Temperature sensor
filter rod formation.
It follows for temperature rising in the electric board back
U6.8 Thermo controller
of the machine).
AIGER CONFIDENTIAL
D000138674
Rev. 05; 09.05.2018
Motors
M6.5
M22.5
M20.5
M6.4
Rear of the machine (middle door)
M75.4.
M34.2
M34.6
Rear of the machine (right door)

Fig. 17
Code Type Function
M20.5 Servo motor Main drive. Operates the main shaft and cut-off knife.
M34.2 Motor Oil pump drive.
M22.5 Servo motor Garniture tape drive
M34.6 Motor Bobbin changer drive.
M6.4 Motor Grinder drive of the front disk.
M6.5 Motor Grinder drive of the rear disk.
Raises or lowers the sealing chamber depending on the
M75.4 Servo motor (Option)
Sikora Laser unit measurement.
AIGER CONFIDENTIAL
D000138674
Rev. 05; 09.05.2018
Motors
M29.5
M24.5 M30.5
M26.5 M34.4
M28.5
Fig. 18
Code Type Function

M29.5 Servo motor Fluted drum drive.
M24.5 Servo motor Tension roller drive.
M34.4
Motor Transfer drum blower.
(option)
M26.5 Motor/ inverter Main blower.
M30.5 Motor/ inverter Bobbin accelerator drive.
M28.5 Servo motor Double accelerator drive.
AIGER CONFIDENTIAL
D000138674
Rev. 05; 09.05.2018
Fans
M92.7
Fig. 19 Ventilators
Code Type Function

M92.7 Fan Cooling of the control panel of the machine.
AIGER CONFIDENTIAL
D000138674
Rev. 05; 09.05.2018
Executive mechanism
Executive mechanism
Y68.1 Y78.7
Y12.3
Fig. 20 Executive mechanisms
Code Type Function

It controls the closed position of the scissors for cutting the filter
Y12.3 Pneumatic distributor rod in opened cover of the rod severer for the purpose of
safety.
Pneumatic distributor It controls the compressed air of the cylinder for operation of
Y68.1
the splice pressure roller.
Pneumatic distributor It controls the compressed air of the cylinder for fixation of the
Y78.7
bobbin changer in working position.
AIGER CONFIDENTIAL
D000138674
Rev. 05; 09.05.2018
Y80.4 Y80.6
Executive mechanism
Y76.2
Y10.4 Y10.6
Fig. 21
Code Type Function

Y80.4 (option) Pneumatic
Distribution block for operation of the glue system SPI.
Y80.6 distributor
Y10.4 Pneumatic Control of the air for the waste of the filters from the
Y10.6 distributor fluted drum.
Y80.5(option) Pneumatic Control of the air for filter elimination from the fluted
Y80.7(option) distributor drum for dry and wet samples.
Y 72.61 Pneumatic
Y 72.62 Control of the knife hood
distributor
Y 72.7
Pneumatic
Y76.2 Distribution block for operation of the transport jet.
distributor
Pneumatic
Y 76.5 Cooling system by pass on/off.
distributor
AIGER CONFIDENTIAL
D000138674
Rev. 05; 09.05.2018
Main drive
U20.5 M20.5
Fig. 22 Assembly description
The main drive of AIGER PRIME RMS consists of:

- Servo invertor U20.5;
- Main servo drive М20.5 with water cooling;
Main servo drive М20.5 with water cooling:

The transmission from the main drive to the main drive shaft is done through a timing belt
The pulley of the main drive covers the whole format range from 60 to 150 mm filter length.
AIGER CONFIDENTIAL
D000138674
Rev. 05; 09.05.2018
General list of applied sensors
Rod maker module

Sends signals to the standstill relay. When
main drive is turning the machine covers
1. S8.1 Inductive proximity sensor are locked, and when the main drive is
stopped, the covers can be opened, as
well as the cooling bar can be operated.
Sends signals to the standstill relay. When
main drive is turning the machine covers
2. S8.2 Inductive proximity sensor are locked, and when the main drive is
stopped, the covers can be opened, as
well as the cooling bar can be operated.
Controls of the filter rod cutting. When
3. S12.2 Magnetic proximity sensor closing the cover of the rod severer the
filter rod is cut.
It controls the drawing out of the paper. It
4. S 24.8 Encoder
regulates the speed of the tension roller.
S 29.1 It controls the synchronization of the fluted
5. Inductive proximity sensor
(option) drum and knife head.
Dynamic control of the filter rods: control
6. S 58.2 Photoelectric sensor of the cut filter rods on higher and lower
level.
It monitors for presence of filter rod before
7. S 58.3 Photoelectric sensor
the diameter control inlet guide.
It creates information for the output
8. S 58.5 Optic sensor
production.
It allows the glue process, when the holder
of the splicing band is turned into working
9. S 76.1 Inductive proximity sensor position. In fulfilling the process of splicing
when the holder is not in working position:
the machine stops.
Control over the pressure of the
compressed air for the machine supply. In
10. S 78.1 Pressure sensor
entry pressure under 4 bar the machine
stops and it brings an error message.
It controls the position of the bobbin
changer after turning: it stops the motor
11. S 76.3 Inductive proximity sensor
and gives a signal for fixation from the
locking mechanism.
Control over the pressure of the
compressed air for the supply of the
12. S 76.4 Pressure sensor transport nozzle. In entry pressure under 3
bar the machine stops and it brings an
error message.
It allows the bobbin changer glue process,
13. S 76.5 Optic sensor when the used bobbin paper reaches the
assigned minimal diameter (right position).
AIGER CONFIDENTIAL
D000138674
Rev. 05; 09.05.2018

Control of the oil pressure, when the
14. S 72.6 Pressure sensor pressure is under 0.6 bars it submits a
signal for machine operation stopping.
It starts the bobbin changer turning, when
15. S 76.7 Photoelectric sensor the used bobbin paper reaches the
assigned minimal diameter (left position).
If follows for the position of the cylinder,
16. S 76.8 Magnetic sensor
which activates the locking pin.
It follows the output of the machine for
17. S 72.4 Inductive proximity sensor
overloading.
It follows the temperature of the garniture
18. S 91.2 Thermal proximity sensor
top.
It follows the temperature of the cooler for
19. S 91.4 Temperature sensor
the filter rod formation.
AIGER CONFIDENTIAL
D000138674
Rev. 05; 09.05.2018
Operating messages
No Discrete message / English Action

1 AML>AIGER ENGINEERING LTD. <No value>
RMM>EMERGENCY STOP CONTROL PANEL Actuated emergency stop on the RMM Main
PUSHED - B10.1 control panel. Unlock the emergency stop-B10.1.
2
Push the start main drive button from RMM Main
control panel-B82.4.
RMM>EMERGENCY STOP FLUTED DRUM AREA Actuated emergency stop on the RMM fluted
PUSHED - B10.2 drum area. Unlock the emergency stop-
3
B82.4.Push the start main drive button from RMM
Main control panel-B10.2
RMM>COOLING FAN MAIN FRAME CIRCUIT Check fan M4.7 for short circuit between signals
4
BREAKER OVERLOAD - F4.7 380 and 01.
RMM>STANDSTILL RELAY FAULT - K8.2 Monitoring. Standstill monitor function fails.
Machine standstill signalled to PLC although the
machine is in operation. Call service Engineer.
*Check connections to Safety standstill relay-
5
K8.2
*Check condition of Safety standstill relay-K8.2
LED's.
*Internal error or broken relay-k8.2
RMM>EMERGENCY STOP RELAY RESET All RMM covers are closed and there is not
REQUIRED - K10.2 pushed Emergency Stop. Push the start main
6
drive button from RMM Main control panel-
B82.4.
RMM>PHASE DETECTION RELAY ACTIVATED - There is problem with phase deduction relay-
K2.1 K2.1
Call Service engineer.
*Check power supply deviation-Nets R17,S17,
7 T17
*Check all phases appearance-Nets R17,S17,
T17
*Check phases sequence-Nets R17,S17, T17
*Check fuses -FA2.21,FA2.22,FA2.23
RMM>PHASE DETECTION RESET REQUIRED - Push the start main drive from RMM Main control
9
K2.1 panel - B82.4 button to reset error.
RMM>STANDSTILL MONITOR FAULT - K8.2 Monitoring. Standstill monitor function fails.
Machine standstill signalled to PLC although the
machine is in operation. Call service Engineer.
*Check connections to Safety standstill relay-
10
K8.2
*Check condition of Safety standstill relay K8.2
LED's.
* Check connection Sensors- S8.1 and S8.2
RMM>GARNITURE TAPE DRUM GUARD IS Garniture tape drum cover is open.
11
OPEN - S14.7C Close the cover.
RMM>SAFETY DOORS ARE NOT Garniture tape guard hood not get interlocked.
CLOSED.CHECK ALL DOORS AND PRESS RESET *Check the Safety sensor S14.7 position of the
BTN. manual locking. Reset manual locking position.
12
*Check guard correctly closing.
*Check the Safety sensor S14.7 position of the
manual locking.
13 RMM>FLUTED DRUM GUARD IS OPEN - S14.2 Fluted drum cover is open.
AIGER CONFIDENTIAL
D000138674
Rev. 05; 09.05.2018
Close the cover.

RMM>FLUTED DRUM REAR GUARD IS OPEN - Fluted drum guard not get interlocked.
S14.5 Call service engineer.
*Check the safety sensor S14.5 position of the
manual locking. Reset manual locking
14
position.
*Check guard correctly closing.
*Check the safety sensor S14.5 position of the
manual locking.
15 TOM IS NOT READY Check TOM condition.
RMM>ROBATECH GLUE SYSTEM CIRCUIT Check the Robatech glue system. Check the
16
BREAKER TRIPPED- F35.2 breaker.
17 RMM>WRONG SHIFT TIME Wrong shift time. Check settings on screen 7
18 RMM>KNIFE HOOD IS OPEN - S14.3C Knife hood is open. Close the hood.
RMM>KNIFE HOOD NOT GET INTERLOCKED - Knife hood not get interlocked. Call service
S14.3I engineer. *Check the Safety sensor S14.3
19
position of the manual locking. Reset manual
locking position.
RMM>SMOKE DETECTION SYSTEM IS Fire system is activated-S65.1. Check knife head
20 ACTIVATED-S16.8.CHEK KNIFE HEAD condition.
CONDITION.
21 RMM>HOT MELT NORDSON IS NOT READY Check NORDSON condition.
RMM>MAIN DRIVE REAR DOOR IS OPEN - Main drive rear guard is open.
23
S16.6 Close the guard.
RMM>RIGHT REAR DOOR IS OPEN - S16.5 Right rear door is open.
24
Close the door.
RMM>GARNITURE TAPE SERVICE COVER IS Left switch cabinet door is open.
27
OPEN -S14.4 Close the door.
RMM>HOT MELT SYSTEM IS NOT READY. Check Robatech device.
31
CHECK DEVICE
RMM>HOT MELT SYSTEM MESSAGE E[<tag Check device help status screen
32 Rob_Error_N>].CHECK DEVICE HELP STATUS
SCREEN
RMM>HOT MELT SYSTEM TEMP. LOWERING IS Switch on heaters or check temperature settings
33 ACTIVE. SWITCH ON HEATERS OR CHECK
TEMP. SETTINGS
RMM>HOT MELT TANK-EMPTY.ADD Add granulate
34
GRANULATE
RMM>HOT MELT TANK-EMPTY.ADD Add granulate
35
GRANULATE
RMM>HOT MELT SYSTEM WORKING Please wait
36
TEMPERATURE IS NOT REACHED. PLEASE WAIT
RMM>HOT MELT SYSTEM IS NOT ONLINE- Parameter 400 is OFF
37
PARAMETER 400 IS OFF
RMM>HOT MELT SYSTEM GRANULATE EMPTY. Add granulate in container
38
ADD GRANULATE IN CONTAINER
RMM>HOT MELT SYSTEM GRANULATE EMPTY. Add granulate in container
39
ADD GRANULATE IN CONTAINER
RMM>HOT MELT SYSTEM-P1-- PREADY. PUMP1 Pump1 pressure is not ready
40
PREASURE IS NOT READY
RMM>HOT MELT SYSTEM-P2-- PREADY. PUMP2 Pump2 pressure is not ready
41
PREASURE IS NOT READY
AIGER CONFIDENTIAL
D000138674
Rev. 05; 09.05.2018
RMM>PROFIBUS PARTNER COMMUNICATION Address 5 / Robatech system

43 ERROR-ADDRESS 5/ROBATECH SYSTEM.
CHECK DIAGNOSTIC STATUS ON SCREEN 4.7
46 >>MTF IS NOT READY Check MTF condition.
47 >>EMERGENCY IN LINE IS ACTIVATED Release Emergency stop and press RESET.
RMM>AMK RMM POWER MODULE TRIPPED. See AMK errors info screen
48
SEE AMK ERRORS INFO SCREEN
RMM>CIRCUIT BREAKER OIL PUMP TRIPPED - Oil pump-M34.2 circuit breaker is overload.
Q34.2 Call electrical engineer to check circuit breaker
55 condition.
*Check connections R30, S30, T30 while
contactor K34.2 is switched on for short circuit.
RMM>CIRCUIT BREAKER BOBBIN SWIVEL PLATE Bobbin swivel plate drive-M34.6 circuit breaker
TRIPPED - Q34.6 is overload Call electrical engineer to check
56 circuit breaker condition.
*Check connections R32,S32,T32 while contactor
K34.6 is switched on for short circuit
RMM>CIRCUIT BREAKER TRANSFER DRUM Transfer drum blower drive-M34.4 circuit
BLOWER TRIPPED - Q34.4 breaker is overload Call electrical engineer to
57 check circuit breaker condition.
*Check connections R31,S31,T31 while contactor
K34.4 is switched on for short circuit
RMM>DIAMETER CONTROL HEATER CIRCUIT Check F46.3
59
BREAKER TRIPPED- F46.3
60 RMM>HOMING IN POGRESS. PLEASE WAIT Please wait
RMM>PVA SEAM GLUE MOTOR OVERLOADED PVA Seam Glue stepper motor overload
61 indication 10 s after motor start. Call electrical
engineer to check U33.5 fuse
RMM>PVA INNER GLUE MOTOR OVERLOADED PVA Inner Glue stepper motor overload
62 indication 10 s after motor start. Call electrical
engineer to check U33.2 fuse
RMM>MAIN DRIVE INVERTER TRIPPED -U20.5 . Main drive Inverter trip-U20.5.Call electrical
67 SEE AMK ERRORS INFO SCREEN engineer.*Check fuses -F19.1 condition .Push
machine Start button to Reset Error.
RMM>GARNITURE TAPE DRUM INVERTER Garniture tape drum drive Inverter trip-
TRIPPED - U22.5. SEE AMK ERRORS INFO U22.5.Call electrical engineer.*Check fuses -
68
SCREEN F19.1 condition .Push machine Start button to
Reset Error.
RMM>PAPER TENSION INVERTER TRIPPED - Paper tension drive Inverter trip-U24.5.Call
U24.5. SEE AMK ERRORS INFO SCREEN electrical engineer.*Check fuses -F19.1
69
condition .Push machine Start button to Reset
Error.
RMM>BLOWER INVERTER TRIPPED - U26.5. SEE Blower Inverter trip-U26.5 .Call electrical
70 AMK ERRORS INFO SCREEN engineer.*Check fuses -F19.1 condition .Push
machine Start button to Reset Error.
RMM>DOUBLE ACCELERATOR INVERTER Double accelerator drive Inverter trip-
TRIPPED -U28.5. SEE AMK ERRORS INFO U28.5.Call electrical engineer.*Check fuses -
71
SCREEN F19.1 condition .Push machine Start button to
Reset Error.
RMM>BOBBIN ACCELEARATOR INVERTER Bobbin accelerator drive Inverter trip-U30.5
TRIPPED -U30.5. SEE AMK ERRORS INFO .Call electrical engineer.*Check fuses -F19.1
72
SCREEN condition .Push machine Start button to Reset
Error.
AIGER CONFIDENTIAL
D000138674
Rev. 05; 09.05.2018
RMM>SEAM GLUE INVERTER TRIPPED-U32.3. Seam glue drive Inverter trip-U32.3.Call

SEE AMK ERRORS INFO SCREEN electrical engineer.*Check fuses -F19.1
73
condition .Push machine Start button to Reset
error.
RMM>DAUBER SYSTEM INVERTER TRIPPED - Press RESET button.
74
U25 SEE AMK INFO SCREEN Call service engineers.
RMM>VALVES POWER SUPPLY CIRCUIT Outputs operation power circuit breakers trip.
BREAKER TRIPPED - F4.8 Circuit breaker F4.8 is switched off.
75 Call electrical engineer to check circuit breaker
condition.
*Check connections 242-01 for short circuit
RMM>TRANSFORMER CIRCUIT BREAKER Transformer circuit breaker trip. Call electrical
TRIPPED - Q6.2 engineer to check circuit breaker condition.
76
*Check connections to transformer (R5-S5) for
short circuit
RMM>GRINDING WHEELS CIRCUIT BREAKER Grinding wheels circuit breaker trip. Circuit
TRIPPED - F6.3 breaker F6.3 is switched off. Call electrical
engineer to check circuit breaker condition.
77
*Check connections to grinding wheels drives
(405-NT)
for short circuit while K6.4 is switched on.
RMM>ANTISTATIC DEVICE CIRCUIT BREAKER Antistatic device circuit breaker trip. Circuit
TRIPPED - F6.5 breaker F6.5 is switched off. Call electrical
engineer to check circuit breaker
78
condition.*Check connections to antistatic device
(404-NT) for short circuit while K6.6 is switched
on.
RMM>CABINET COOLING UNIT CIRCUIT Cabinet cooling unit circuit breaker trip F6.7.Call
BREAKER TRIPPED- F6.7 service engineer.*Check for short circuit (S9-NT)
.*If there is not short circuit breaker check cooling
81
unit condition -U6.7.Check pressure sensor in the
cooling unit. Push reset button and turn on circuit
breaker.
RMM>P241 POWER SUPPLY CIRCUIT BREAKER Operation Power supply (Digital inputs) circuit
83 TRIPPED - F4.3 breaker trip F4.3. Call service engineer.
Check for short circuit (241-01).
RMM>P242 POWER SUPPLY CIRCUIT BREAKER Operation Power supply (Digital outputs) circuit
RMM>P243 POWER SUPPLY CIRCUIT BREAKER Operation Power supply (Safety system) circuit
RMM>HOT MELT CHAMBER Hot melt chamber on the bottom over
OVERTEMPERATURE(ROBATECH) temperature. Switch off heaters. Call service
87 engineer.
Check alarm level settings-screen 4.1.2 Service
data temperature
RMM>MEASURING TUBE OVERTEMPERATURE - Measuring tube over temperature. Switch off
90 RT50.3, S50.3 heaters. Call service engineer. Check alarm level
settings-screen 4.1.2 Service data temperature
RMM>GLUE GUN HEATER OVERTEMPERATURE Hot melt glue gun over temperature. Switch off
91 (ROBATECH) heaters. Call service engineer. Check alarm level
AIGER CONFIDENTIAL
D000138674
Rev. 05; 09.05.2018
RMM>HOT MELT HOSE OVERTEMPERATURE Hot melt hose over temperature. Switch off
93 (ROBATECH) heaters. Call service engineer. Check alarm level
RMM>INVERTERS INITIALISATION Machine is in standstill mode. After emergency
95
system reset wait for Inverters initialization
PROFIBUS COMMUNICATION ERROR - U35 Check the link between ROBATECH system and RMM
97 PLC.
HOT MELT ROBATECH SYSTEM
RMM>DRIVES ARE UNLOCKED. LOCK THE Lock the drives.
101
DRIVES
RMM>PROFINET FAULT MONITORING BUS Check connection.
102 MEMBER OTM - CSM. CHECK CONNECTION.
CHECK DIAGNOSTIC STATUS ON SCREEN 4.7
103 MEMBER ACM. CHECK CONNECTION. CHECK
DIAGNOSTIC STATUS ON SCREEN 4.7
104 MEMBER TOM. CHECK CONNECTION. CHECK
105 MEMBER OIM. CHECK CONNECTION. CHECK
RMM>UDP FAULT MONITORING BUS MEMBER Check connection. Push reset button.
106 - A5 INVERTERS CONTROLLER. PUSH RESET
BUTTON
RMM>INVERTERS START UP AND NETWORK Please wait.
107
ESTABLISHMENT.PLEASE WAIT....
108 MEMBER ALM. CHECK CONNECTION. CHECK
RMM>PAPER HEATER UNIT TEMPERATURE TOO Wait until T goes in the limit.
126
LOW - RT50.1,S50.1
RMM>MEASURING TUBE HEATER UNIT Measuring tube heater unit temperature is too
TEMPERATURE TOO LOW - RT50.3, S50.3 low.
128 If temperature is not reached after 5 minutes
check S50.3. Wait until the set point
temperature is reached.
RMM>GLUE GUN HEATER UNIT TEMPERATURE Glue gun heater unit temperature is too low.
TOO LOW(ROBATECH) Wait until the set point temperature is reached.
129
If temperature is not reached after 5 minutes
check S50.5
RMM>CHECK AND ADJUST FILTER ROD Warning message. Check and adjust filter rod
130 OVERLAPPING .CLEAN BOOLET ROLLER. overlapping; clean bullet roller; automatic
AUTOMATIC DIAMETER CONTROL IS OFF. diameter control is OFF.
RMM>GLUE HOSE HEATER UNIT TEMPERATURE Glue hose unit temperature is too low.
TOO LOW( ROBATECH) Wait until the set point temperature is reached.
131
If temperature is not reached after 5 minutes
check S48.6
RMM>AUX. DRIVES OFF BUTTON PUSHED Auxiliary drives (Blowers, Oil pump) must be
134 started. Push Auxiliary drives Start button from
RMM Main Control Panel.
RMM>HEATING IS SWITCHED OFF Machine heaters are switched off. Push Heating
on button from KDF Main Control Panel to start
135
heaters to run machine in "MATERIALS ON"
mode
AIGER CONFIDENTIAL
D000138674
Rev. 05; 09.05.2018
RMM>OIL PRESSURE TOO LOW - S72.6 Oil pressure is too low or Oil pressure switch
137 S72.6 is not adjusted. Call service engineer to
check oil pressure and pressure switch.
RMM>COMPRESSED AIR TOO LOW - S78.1 Compressed air is too low or Air pressure switch
138 S78.1 is not adjusted. Call service engineer to
check air pressure and pressure switch.
RMM>TRANSPORT JET COMPRESSED AIR TOO Transport Jet air supply is too low. Switch on
149 LOW - S76.4 power supply or call service engineer to adjust
pressostat-S76.4
RMM>CONTROL PANEL FAN CIRCUIT BREAKER Control Panel(IPC477D) circuit breaker tripped
- F92.7 -F92.7
152
Call electrical engineer to check for short circuit
or current overload(374-01)
RMM>MAIN CABINET COOLING FAN CIRQUIT Switch ON the circuit breaker; check the reason
153 BREAKER F4.7 for the OFF state.
Call service engineers.
RMM>DIAMETER CONTROL OVERPRESSURE AT Diameter control overpressure on the P/U
155
P/U CONVERTER - Y68.63 Converter (Halstrup).
RMM>DIAMETER CALIBRATION NOT FINISHED Diameter measure calibration is not finished.
156 Finish calibration.
Set Measure value and set button calibration.
157 RMM>DIAMETER CALIBRATION FINISHED Diameter calibration is finished
RMM>INDEX BOLT NOT IN UNLOCK Index bolt not in position.
158
POSITION- S76.8 Call Service Engineer.
RMM>LEFT BOBBIN IS EMPTY - S76.7 Add new one or call service engineer to check
159
S76.7 adjustment
RMM>SPLICE PATCH HOLDER IN POSITION Splice patch holder was rotated in without left
160
WITHOUT NEW BOBBIN - S76.1 bobbin. Add left bobbin
RMM>BOBBIN SWIVEL PLATE TURNED TOO Bobbin swivel plate. Operating time monitoring.
161
LONG Call service engineer.
RMM>BOBBIN SWIVEL PLATE IS NOT IN STOP Bobbin swivel plate is not in stop position. Stop
162
POSITION - S76.3 aux. drives; rotate the plate to his initial position
RMM>DIAMETER CONTROL P/U CONVERTER P/U converter S74.7 measure is too low.
164
OR MEASURING AIR FAULT Call service engineer
RMM>DIAMETER CONTROL P/U CONVERTER P/U converter measure is too high.
165
FAULT Call service engineer.
RMM>ROD MONITORING STATIC ROD BREAK Static rod monitoring. Break in rod. Clean
166 - S58.3 machine.
Call service engineer to check S58.3 adjustment.
RMM>FLUTED DRUM SYNCHRO PULSE FAILURE There is no synchro pulses from sensor S29.1 on
- S29.1 exit area for 3 turnovers of the knives head. Call
Service engineer. Check if fluted drum rotating.
167
Check sensor S29.1 adjustment .it must be
on <2mm from metal actuator (channels of
fluted drum)
RMM>KNIFE ADVANCE STOPPED. REPLACE Change knives. Push Main drive run button while
168 KNIVES Knife hood is open.
Then close the hood.
RMM>ROD MONITORING DYNAMIC ROD Dynamic rod monitoring. Break in rod. Clean
BREAK - S58.2 machine. Call service engineer to check S58.2
169
adjustment. In case of basic rod sensor must be
switched on.
RMM>CONVEYOR BELT FULL- S72.4 Output Overfill. Check next machine condition.
170
Call service engineer. Check adjustments of the
AIGER CONFIDENTIAL
D000138674
Rev. 05; 09.05.2018
sensor
S72.4 It must be on >2mm from metal actuator
171 RMM>FILTER COUNTER FAILURE - S58.5 Adjust sensor S58.5.
RMM>SEAM GLUING: GLUE TEST ACTIVE Hot melt seam gluing test active. Please turn
173 switch (from the Main RMM Control Panel)in
automatic mode to start machine
RMM>PVA SEAM GLUING: GLUE TEST ACTIVE( PVA seam gluing test active.
174
1.7.5)
RMM>MEASURED DIAMETER IS TOO HIGH Measured diameter is too high. Decrease
176 manually diameter, check diameter settings on
the panel or check automatic diameter control.
RMM>MEASURED DIAMETER IS TOO LOW Measured diameter is too low. Increase
177 manually diameter, check diameter settings on
the panel or check automatic diameter control.
RMM>DIAMETER CALIBRATION IN PROGRESS Warning message. It's going diameter control
181
calibration
RMM>DIAMETER CONTROL IN MANUAL MODE Warning message. Diameter control is in manual
182 mode via switch of the RMM Main control panel.
You can manually calibrate diameter
183 RMM>PRETENSIONING ACTIVE Filter paper pretension active
184 RMM>KNIFE ADVANCE WARNING Knife change imminent
RMM>DOWNSTREAM MACHINE IS NOT Manual mode is selected via Optima Panel-
185 READY Change mode to Automatic; Stop mode is
selected -Start machine.
RMM>DIAMETER CONTROL ERROR. CHECK Check and clean the diameter control device=
186
DEVICE
RMM>HOLD START. PROGRAM WAITING FOR Machine is in Start Program mode, but there is
192
STATIC ROD MONITOR no rod cut off
RMM>HOLD START PROGRAM WATING FOR Machine is in Start Program mode. Waiting Rod
196
ROD CUT ON cutter. Close the rod cutter.
RMM>ROD CUTTER NOT IN OFF POSITION When the machine is in standstill condition, close
197
rod cutter hood to can the scissors lift up.
RMM>MAIN DRIVE STOP BUTTON PUSHED Main drive OFF actuated. Immediately stop
198
actuated
RMM>FLUTED DRUM INVERTER TRIPPED - U29.5 Call electrical engineer
199 *Check fuses -F19.1 condition. Push machine
Start button to Reset Error
RMM>ROD PATH TAPE TENSION IS NOT Pull the tensioner.
200
PULLED - Q33.2
203 RMM>SEAM GLUING IS SWITCHED OFF Hot melt glue is switched Off. Turn in On mode
RMM>PVA SEAM GLUING IS SWITCHED OFF PVA glue is switched Off. Turn in On mode
204
(1.7.5)
RMM>TEMPERATURE INSIDE THE ENCLOSURE Temperature is too high. Check filters, cabinet
208 TOO HIGH - U6.8 cooling system and thermocontroller settings-
U6.8
RMM>SPLICE PATCH IS BLOCKED - S76.1 Splice Patch is blocked .Disengage splice patch
209
and Push Main drive start button
RMM>DRIVE DRAG, MAIN DRIVE. THE DRIVE IS Knife head mechanical problem. Call service
211
MECHANICALLY BLOCKED - M20.5 engineer
RMM>RECESS HOT MELT HOSE TEMPERATURE Recess hot melt hose temperature is too high
212
IS TOO HIGH
RMM>RECESS HOT MELT HOSE TEMPERATURE Recess hot melt hose temperature is too low
213
IS TOO LOW
AIGER CONFIDENTIAL
D000138674
Rev. 05; 09.05.2018
RMM>RECESS HOT MELT NOZLE TEMPERATURE Recess hot melt nozzle temperature is too high
214
IS TOO HIGH
RMM>RECESS HOT MELT NOZLE TEMPERATURE Recess hot melt nozzle temperature is too low
215
IS TOO LOW
RMM>BOBBIN SWIVEL PLATE IS TURNING Warning. Attention!!!! Bobbin swivel plate is
217
turning.
RMM>PVA INNER GLUING: GLUE TEST ACTIVE It's going inner gluing test. Switch off inner gluing
218
test
219 RMM>PVA INNER GLUING IS SWITCHED OFF Switch on in automatic mode Inner gluing
RMM>GARNITURE TOP COOLING Check cooling unit. Call service engineer.
222
OVERTEMPERATURE - S91.2 Check sensor Pt100-S91.2.
RMM>GARNITURE BED COOLING Check cooling unit. Call service engineer.
223
OVERTEMPERATURE - S91.4 Check sensor Pt100-S91.4.
RMM>GARNITURE TOP TEMPERATURE IS TOO Switch off heating via Main Control Panel. Call
224 HIGH - S91.2 service engineer.
Check the heating components.
RMM>GARNITURE BED TEMPERATURE IS TOO Switch off heating via Main Control Panel. Call
225
HIGH - S91.4 service engineer. Check the heating components.
RMM>CAM CONTROLLER ENCODER WIRE CAM Controller encoder wire break or missing
BREAK pulses.
228
Call service engineer. Check connections from
CAM sockets to encoder or CAM controller.
RMM>CAM CONTROLLER INTERNAL FAULT- CAM Controller encoder wire break or missing
229
U94.1/CLASS-/NUMBER pulses.
232 RMM>JOG MAIN DRIVE - B81.5 Machine is running in Jog mode
RMM>MAIN DRIVE SPEED NOT REACHED - 25s after Main drive High Program speed
234 M20.5 enable, drive cannot reach set speed.
Call service engineer.
RMM>INDEX BOLT NOT IN LOCK POSITION - Sensor S76.8 what is looking for the index bolt
S76.8 position
(Locking of the Bobbin swivel pate) is not
235 switched on. Call service engineer.
Check index bolt position and check adjustment
of the sensor. It must on less then 2mm from the
metal actuator(Index bolt)
238 RMM>ACM IS NOT READY Check ACM condition.
RMM>MATRIX NEO IS NOT READY OR REJECT There is no communication with Matrix Neo.
239
IS NOT CORRECT Call service engineer.
DIAMETER CONTROL HEATING WIRE BREAK There is wire break from the heater unit sensor.
240 S50.3 Call service engineer. S50.3 of the diameter
control to the 8 channel controller - U52.2.
241 RMM>ALM IS NOT READY Check ALM condition.
242 RMM>ALM EMERGENCY STOP IS PUSHED Release Emergency Stop and press Reset.
243 RMM>TOM IS NOT READY Check TOM condition.
245 RMM>ACM EMERGENCY STOP IS PUSHED Release Emergency Stop and press Reset.
246 RMM>OIM IS NOT READY Check OIM condition
RMM>OIM EMERGENCY STOP IS PUSHED - Release Emergency Stop and press Reset.
247
S8.6
RMM>OIM SAFETY COVERS ARE NOT CLOSED Close and lock the covers.
248
OR INTERLOCKED
249 RMM>OTM-CSM ARE NOT READY Check the condition of OTM-CSM.
RMM>OTM-CSM EMERGENCY STOP IS <No value>
250
PUSHED
AIGER CONFIDENTIAL
D000138675
D000138675 Adjustment of the machine
Rev. 02; 05.07.2018
6 Adjustment of the machine ..........................................................................6.1

6.1 Preface..........................................................................................................6.1
6.1.1 Chapter objective .................................................................................................. 6.1
6.1.2 Chapter purpose ................................................................................................... 6.1
6.2 Process description of the Rod maker module .............................................6.2
6.3 Adjusting the timing belt..............................................................................6.5
6.4 Paper feed ....................................................................................................6.7
6.4.1 Process description ................................................................................................ 6.7
6.4.2 Bobbin changer...................................................................................................... 6.9
6.4.3 Bobbin brakes ..................................................................................................... 6.10
6.4.4 Splicer .................................................................................................................. 6.12
6.4.5 Loop roller ........................................................................................................... 6.14
6.4.6 Paper guides ....................................................................................................... 6.15
6.4.7 Rolling guides ...................................................................................................... 6.17
6.4.8 Exit guide ............................................................................................................. 6.18
6.4.9 Tension roller ....................................................................................................... 6.19
6.4.10 Splicing .............................................................................................................. 6.20
6.4.10.1Process of splicing .......................................................................................... 6.22
6.4.10.2 Speed for performing change of the bobbins ........................................ 6.23
6.4.10.3 Splice and ejection ....................................................................................... 6.24
6.5 Gluing process ...........................................................................................6.26
6.5.1 Process description ............................................................................................. 6.26
6.5.2 Glue tank and nozzles ....................................................................................... 6.27
6.5.3 Start the machine ................................................................................................ 6.28
6.6 Forming the filter rod .................................................................................6.32
6.6.1 Stages of forming the filter rod ....................................................................... 6.32
6.6.2 Garniture tongue adjustment procedure (steps) ........................................... 6.33
6.6.3 Garniture tape drum.......................................................................................... 6.35
6.6.4 Garniture tape .................................................................................................... 6.36
6.6.4.1 Garniture tape adjustments .......................................................................... 6.38
6.6.4.2 Garniture tape change .................................................................................. 6.38
6.6.5 Sealing the filter rod ......................................................................................... 6.39
6.6.6 Automatic rod formation with sealing chamber (Cooling bar) ................... 6.40
6.6.7 Filter rod heating ............................................................................................... 6.44
6.6.8 Filter rod cooling ................................................................................................ 6.45
6.7 Cut-off unit .............................................................................................................. 6.47
6.7.1 Instruments and gauges for setting the filter way ........................................ 6.48
6.7.2 Straight filter way adjustment .......................................................................... 6.49
6.7.3 Ledger holder ..................................................................................................... 6.50
6.7.4 Installing and adjusting the ledger holder ..................................................... 6.51
6.7.5 Installation of the arm ........................................................................................ 6.52
6.7.6 Installing and adjusting of the guide tube ..................................................... 6.53
6.7.7 Installing and adjusting the diameter control nozzle .................................... 6.54
AIGER CONFIDENTIAL
Page 6.i www.aiger.com
D000138675
Rev. 02; 05.07.2018
6.7.8 Adjusting the cutting ledger tubes ................................................................... 6.55

6.7.9 Adjusting the cutting ledger stroke at different filter length ...................... 6.56
6.7.10 Installing the knife carrier ............................................................................... 6.58
6.7.10.1 Technical maintenance of the knife holders ............................................. 6.58
6.7.11 Adjusting the filter rod cutting ....................................................................... 6.59
6.7.12 Adjusting the angle of the knife carrier ....................................................... 6.60
6.7.13 Knife sharpening .............................................................................................. 6.61
6.7.14 Automatic knife advance unit ......................................................................... 6.62
6.7.15 Adjustment of the knife advancing mechanism............................................ 6.63
6.7.16 Knife sharpening .............................................................................................. 6.65
6.7.17 Adjusting the sharpening disks angle ........................................................... 6.66
6.7.18 Knife carrier safety cover............................................................................... 6.68
6.8 Filters acceleration .....................................................................................6.69
6.8.1 Function................................................................................................................. 6.70
6.8.2 Double accelerator ............................................................................................ 6.71
6.8.3 Filters transfer ..................................................................................................... 6.73
6.8.4 Fluted drum.......................................................................................................... 6.74
6.8.5 Producing a filter rod for fluted drum adjustments ...................................... 6.75
6.8.6 Table of parameters for setting the catching ................................................ 6.76
6.8.7 Transfer drum ...................................................................................................... 6.77
6.8.8 Output transport ................................................................................................. 6.78
6.8.9 Antistatic bar ....................................................................................................... 6.79
6.8.10 Filter ejection .................................................................................................... 6.80
6.8.10.1 Filter ejection at machine stop .................................................................... 6.81
6.8.10.2 Filter ejection at bobbin splice ................................................................... 6.82
6.9 Lubrication system .....................................................................................6.83
6.9.1 Function of the lubrication system .................................................................... 6.84
6.9.2 Oil change ........................................................................................................... 6.85
6.9.3 Oil fill.................................................................................................................... 6.85
6.10 Pneumatic system ....................................................................................6.86
6.10.1 Description of the pneumatic systems ........................................................... 6.86
6.10.2 Pneumatic group .............................................................................................. 6.88
6.11 Cooling system ........................................................................................6.89
AIGER CONFIDENTIAL
Page 6.ii www.aiger.com
D000138675
Rev. 02; 05.07.2018
6 Adjustment of the machine
6.1 Preface

- Mechanical adjustments of machines assemblies
- Information on the function of the different assemblies

- Service staff
- QA staff
- Maintenance staff
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
6.2 Process description of the Rod maker module

The process of forming the filter rod and the filter is shown on the diagram below:
7 Tow way in 4
8
5
6
2
3
New bobbin 1
Working paper
(fig.1)
Process description of the Rod Maker Module
The process can be divided basically in 9 zones:
Zone 1 – Paper supply
The bobbin changer automatically rotates to place a new bobbin. When the working bobbin reaches a
minimal diameter a bobbin splicing process begins - the bobbin splicer splices the new paper to the working
paper. The splicing is done with a two-side adhesive tape. The paper at the point of splicing is cut off and
thrown away in a container.
The pulling roller aids in feeding the filter paper to the transport band.
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018

The pulling roller aids in feeding the filter paper to the transport band. Transport jet
7 Tongue
Cooling unit
4
8 5
2
Format garniture 3
9
(fig.1)
Zone 3 – Glue application on the paper

The glue system applies several stripes of glue on the filter paper. This can be done by a hot melt nozzle, PVA
nozzle or a combination of the two. The function of the glue system is to form the seam of the filters, as well as for
splicing the tow to the filter paper.
Zone 4 – Forming the filter rod

From the upstream machine AIGER FLEX TOM, through a transport jet treated tow is supplied to the format
garniture tongue piece. After that the tow and the filter paper are carried inside the format garniture. A cooling
unit seals the filter rod.
Zone 5 – Measuring the filter rod

During working of the machine, the diameter control nozzle measures the filter rod diameter.
Zone 6 – Cutting off the filter rod

A knife head with two knives cuts the filter rod into separate filters.
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
7
5 Cooling unit 4
8
6
2
Format garniture 3
9
1
New bobbin
Working paper
(fig.1)
Zone 7 – Accelerating the filters

The cut by the knife head filters are accelerated by a double accelerator to the fluted drum.
Zone 8 – Transferring the filters

The transfer drum takes the filters from the filter drum and passes them to the output transport.
Zone 9 – Output transport

The output transport transports the filters from the transport drum.
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
6.3 Adjusting the timing belt

Loosen the four screws (1) on the main drive. Turn the main drive so that the toothed belt is brought under
tension and re-tighten the screws. To check that you have the correct belt tension, use a spring balance and pull
the toothed belt 2 mm downwards with a force of 12.3 N.
(fig.2)
Adjusting the timing belt transmission
For precise adjustment you may order Trummeter (catalogue number 111100)
from company Aiger Engineering Ltd and measure the tension of the belt.
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
Belts pre-tension
Unit Main drive

Catalogue number of
114106
belt
Type of belt 720-8M-20

Length of measured
224
stand [m]
Natural frequency of
belt [Hz] 91
min
max 100
Pre-tension [N] 243
Unit Swivelling plate
Catalogue number of
108732
belt
Type of belt SPZ Lw=662

Length of measured
168
stand [m]
belt [Hz] 58
min
max 71
Pre-tension [N] 208
ATTENTION! The measurement position is always at the longest part of the belt
drive between 2 pulleys. Calculation are based on measurement with Trummeter
produced by Hilger u. Kern GmbH
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
6.4 Paper feed
6.4.1 Process description
All the assemblies and mechanisms for paper feeding are designed in such way to provide a continuously
feeding during the operating of the machine.
The process of paper feeding is performed by the following devices and assemblies of the Rod module
- Device for automatic bobbin change /bobbin changer/ (1);
- Mechanism for paper splicing (2);
- Assembly for pulling out the paper with tension roller (3).
-
2
1
(fig.3)
Paper feeding
During machine operation, when it is necessary, the operator places a new bobbin on the left bobbin holder
for the change to begin.
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
(fig.4)
Automatic bobbin change
The automatic bobbin change is performed at four stages, in the following sequence:
 Stage І – the illustrated position is right after the bobbin change: The bobbin (В) on the right is empty.
The bobbin (А) on the left is rolling at the moment. When the diameter of the bobbin (А), decreases
to approximately 250 mm, the device for bobbin change turns the bobbin to 180° in right position.
 Stage ІІ – the position of the bobbin after turning of the bobbin changer.
 Stage ІІІ – While the bobbin (А) keeps rolling, the operator must replace the empty bobbin with a
new one (С). The paper is carried to the splicing device, as it is shown. The paper end is pressed with
a roller to the acceleration roller. A double splicing band is placed on the carrying holder and it is
turned into working position.
 Stage ІV – The working bobbin (А) keeps rolling, until it reaches the minimal diameter, controlled by
optical sensor. Acceleration roller pulls the paper, so the new bobbin accelerates to the speed of the
machine. After papers speeds equalization (papers from the two bobbins), it comes the moment of
conglomeration. The paper wasted during the acceleration is collected in the paper tank.
When this stage is completed the bobbin changer is again in position of Stage І.
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
6.4.2 Bobbin changer
The device for automatic bobbin change is composed of plate (1) and two bobbin holders – left (A) and
right (B).
5 В
А
4 6
(fig.5)
Bobbin changer
The paper bobbin is placed on the left bobbin holder and is centred by the cone (2). It is pressed by a nut
(4).
The pressing nut (4) is with left hand threading. That protects it by self-loosening
during bobbins rotation.
Bobbin holder (A)

When the bobbin diameter (А) decreases to about 250 mm, the bobbin changing device turns it to the right
position. The diameter is controlled by optic sensor (3) – SN76.7.
Bobbin holder (B)

The diameter of bobbin on the bobbin holder (B) is controlled by optic sensor (6) – SN76.5. When the paper
decreases to the assigned diameter for splicing then the reporting stops.
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
Bobbins plate (1)

When activating the inductive sensor SN76.3 from the plunger (5) of the plate, then the process of spinning
stops. The plate is fixed upon locking mechanism. The fixed position of the plate ensures the centring of the
two bobbin holders in horizontal line and the mechanism prevents from spinning the plate in opposite
direction.
The regulation of the plate position is fulfilled through moving the plunger (5) in the oval channel. It changes
the position of the plate trough reporting from the inductive sensor SN76.3.
6.4.3 Bobbin brakes
5 7
22mm 8
4
9
3
2 6
9 8
(fig.6)
Bobbin brakes
The result from regulating the brakes has to be the following:

In pulling the paper with hand the bobbin has to unroll without rupture,
In stopping the machine the bobbin must not spin on inertia.
The regulation of the brakes is allowed only when the bobbin with paper is in left
position.
Regulation of the brake moment

The brake moment of the two bobbins must be at the same time. The regulation is performed in the
following way:
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
Release and turn the cam-bush (1) in a way that the surface of the brake cover-plate (2) to be completely
fitted to the braking flange.
Regulate the distance between the rollers (7) to 22 mm through the cam axle (3) – it has to be the same on
the both operating levers (4);
Release the strip (6) through relaxing the screw (5) and set up the operating lever in a way that the brake
cover-plate still to fit with its entire surface to the braking flange.
Regulate the strip (6) in a way that in this starting position the spring to press the operating lever with
around 2 mm.
In order to change the brake moment, you have to increase or decrease the spring pressure when the
machine is in working mode.
The result from regulating the brakes has to be the following:
In pulling the paper with hand the bobbin has to unroll without rupture,
In stopping the machine the bobbin must not spin on inertia.
In order to check the brake moment you have to use dynamometer (recommended
values 500-700g).
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
6.4.4 Splicer
The splicer guarantees continuously paper feed by attaching the paper from the new bobbin to paper from
the old one.
10 8 9
1 3 7 (fig.7)
2 Splicer
Pressure roller
Through the regulating screw (8) it is adjusted the distance between the pressure roller (3) and the gum
roller (4), which is equal to the double width of the paper. Do the following:
Place between the rollers 4 tapes of filter paper,
Lightly press the rollers one to another and roll the regulating screw to stay condition.
Fix the regulating screw as you tighten up the counter nut.
The maximum swing of the pressure roller must be around 9 mm.
Front paper knife

The distance between the front edge of the knife (1) and the holder for the splicing band /splice patch/ (2)
must be from 2 to 2,5mm. When making regulation the holder has to be turned into working position and
the rollers to be pressed one to another.
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D000138675
Rev. 02; 05.07.2018
Back paper knife

The distance between the knife (10) and the leading roller (7) has to be adjusted from 10 to 12mm through
moving the edge holder (11). The front edge of the knife must be exactly in vertical position over the centre
of the roller.
Holder for the splicing band

Press one to another the pressure roller (3) and roller (4), and after that screw up the regulating screw (9)
to the fixing lever in a way that the lever releases the holder (2) of the splicing band:
The holder must be turned into non-working position.
The distance between the holder of the splicing band (2) and the inductive sensor SN76.1 must be 0.7 mm.
Adjustment of the unit
(fig.7.1)
Do not leave the pressing roller (5) in contact with the acceleration roller (6) when
this is not necessary, this may lead to damaging the roller.
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D000138675
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6.4.5 Loop roller
4
1 3 2
(fig.8)
Loop roller
The loop roller eases the paper after the moment of splicing in the zone.
It is adjusted in the following way:
Loosen the operating lever (3) of the loop roller (2) and regulate in a way that it fits to the front surface of
the releasing lever (1),
Tighten up the operating lever (3) of the loop roller in this position,
Press the pressing roller and the gum roller one to another,
Release the regulative screw (4) till releasing the operating lever (3) of the loop roller. The roller movement
is 5 mm.
Fix again the regulative screw (4).
The paper could be released only after completion of the splicing process. Before the operating lever (3) is
released, the pressure roller must reaches to its end position.
The operating lever of the loop roller must move easily and should not be released
much too early.
If it is necessary unscrew a little the regulative screw (4) in counter-clockwise
direction.
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D000138675
Rev. 02; 05.07.2018
6.4.6 Paper guides
The position of the paper toward the garniture is regulated on the following places:
Bobbin holders (1)
Entry paper guide (2)
Leading roller (3) before the splicing device
Exit guide (4) of the splicing device
1
4
Z
1
5
2
(fig.9)
Paper guides
The paper must enter aligned into the garniture grove. The front side of the machine main frame is basis
surface for paper position adjusting. The distance “Y” from the centre of the garniture (the centre of the paper
in the garniture) to the front side of the machine main frame is 80 mm.
In the splicing device, the papers from both bobbins (new and working one) have to be fed exactly one over
another. Before starting of the paper way adjustment you have to calculate the following distances:
X - Paper width
Y - Distance between the centre of the garniture and the front side of the machine main frame.
Z = (Y - X/2) – Distance between the front side of the paper and the machine main frame.
Example:
Paper width X = 27, 0 mm, Y = 80, 0 mm, Z = 80+13, 5=93, 5 mm
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
Adjustment of the bobbin holders (1)

The dimension “Z” can be changed by rotating the adjustment nut (5).
Rotate nut in clockwise direction - the distance decreases,
Rotate nut in counter-clockwise direction – the distance increases.
Adjustment of the entry paper guide

The entry paper guide must be adjusted according to the width of the paper and the centre of the garniture.
(fig.10)
Entry paper guide
The guide must be adjusted in a way that the distance (X1) between the two leading plates (1) to be equal
to the paper width minus 6 mm, i.e. the paper has to curve a little when it gets over this guide. The width
regulation (Х1) is performed with the help of the screws (2).
Example:
Paper width Х = 27 mm
Distance between the plates Х1 = 27 mm – 6 mm = 21 mm
The distance (Y1) from the back plate to the machine main frame can be adjusted by the setting screw (3).
Rotate the screw in clockwise direction – the distance increases,
Rotate the screw in counter-clockwise direction – the distance decreases.
Example:
The distance between the paper centre and the machine’s main frame is 80 mm.
The distance Y=80 mm, for the paper width 27 mm – the distance Y1=69.5 mm.
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
6.4.7 Rolling guides

1
Y
Z1
(fig.11)
Rolling guides
Adjustment of the rolling guides

The guiding rollers (1) serve for guiding the paper to the splicing device. To the guiding rollers, by means of
the screws are attached restrictive rings:
Adjust the external ring (3) in a way that the distance from the internal surface of the paper channel to the
front side of the machine main frame to be equal to size “Z”. It must be calculated as the following:
Z1 = Y + X/2 Y=80 mm Z = 66.5 mm
After that you have to set the distance between the internal (2) and the external ring (3) “Х”. It must be
exactly equal to the paper width.
The rings must be precisely adjusted – otherwise there will not occur an accurate
guiding of the two paper tapes and the holder of the splicing band might stuck when
it’s spinning.
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D000138675
Rev. 02; 05.07.2018
6.4.8 Exit guide
1 2
(fig.12)
Exit guide
Adjustment of the exit guide

The paper ends must just touch the side guides, during it pass through the exit guide. The guide must be
adjusted in height in a way that the paper fits to the contact surface, on its entire length.
To do that:
Set the guide according to the paper width “Х” using the screws (1),
Through the adjusting screw (2) adjust the distance from the back edge of the channel of the inner plate to
the machine main frame by size “Y2”. It is calculated as the following:
Y2 = Y - X/2 for the paper width 27mm - Y2 = 66.5 mm.
Attend to the parallelity of the guide toward to the machine’s main frame.
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D000138675
Rev. 02; 05.07.2018
6.4.9 Tension roller

The tension roller (3) supports the continuous stretching of the paper in its unrolling from the bobbin.
2 5 3
(fig.13)
Tension roller
The speed of the tension roller (3) is frequency controlled. It depends of the loop rollers position (2).
The position of the loop roller (2) is controlled through encoder U24.8, attached to the axle of the roller’s
shoulder. When shoulder moves to the left or to the right the encoder passes signals to the tension roller control
unit. The purpose is to be supported a continuous stretching of the paper during its passing through the gluing
system and its entry in the garniture. Variations of the paper stretching cause loop roller’s shoulder to swing
to the left or to the right. This changes tension roller (3) speed, so that the loop roller returns to its middle
position.
Adjustment of the loop roller
The adjustment of the roller consists of preliminary bending of the spring that works on twisting. This spring
sets average paper tension (when roller is in its middle position). If stretching is to strong paper may tear.
In order to adjust the spring force:
Take apart the entire flange (1) along with the shoulder and the roller. To do this, you have to remove screws
(5) and coupling at the back of the flange.
Fix in vice the flange with the axle and stretch tight the spring, through spinning in three revs.
Tighten the shoulder at this position with the two screws and install again the assembly.
To setup fine the paper stretching you should change the position of the encoder through screw (4).
Bobbin change sequence
The paper change from old paper with new one passes through several stages:
Spinning the bobbin changer
Placement of the new bobbin with paper
Process of conglomeration
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
6.4.10 Splicing
Initial position of the bobbins
S76.5
S76.7
(fig.14)
Initial position of the bobbins
The initial position of the bobbin holder is with working left bobbin. When optic sensor S76.7 registers a diameter
around 250 mm, the plate starts spinning. On the display is written a message for bobbins change. When it is
turned to 180° the plate is fixed with locking mechanism and the left bobbin holder is already empty. With this
action the process of spinning is accomplished and there can be placed a new bobbin.
In order to adjust the position of the optic sensors, just unscrew the two screws and
move the strip with the sensor till registration of the wanted size of the bobbin.
Change of the bobbins

Before placement of new bobbin, the message to the operator on the display still remains. That means that a new
bobbin has to be placed.
The time from the completion of the bobbin spinning to the beginning of the new
process of passing to the new bobbin is a few minutes. By this reason - right after the
signalization lights up for the necessity of bobbin change, the operator must quickly
place the new bobbin.
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D000138675
Rev. 02; 05.07.2018
3 1 2
S76.1
(fig.15)
Change of the bobbins
After placement of the new bobbin, the operator must prepare the next change of the bobbins:
To carry the paper to the accelerating roller (2) and to press it with the gum roller (1), to put a new splicing
plaster on the splicing band holder to turn holder in position for splicing (the holder has to be registered from
inductive sensor S 76.1). The machine is in ready for splicing mode.
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
6.4.10.1Process of splicing
1 2 3
S76.1
S76.7 S76.3 S76.5

(fig.16)
Bobbin change
 Starting the process of splicing

After the moment of readiness, the process of splicing is starting. The optic sensor S 76.5 that controls the
diameter of the right bobbin passes a signal for accelerating the paper from the left bobbin when the right
one reaches the minimal (assigned) diameter. Left bobbin diameter is monitored by sensor S 76.7.
 Acceleration of the bobbin

During the bobbin changeover process motor M30.5 accelerates the paper from the new bobbin to the speed
of the filter rod. The acceleration and speed are controlled by frequency inverter U30.5.
 Splicing
After paper speeds equalization, control system (PLC) passes an activation signal to the pneumatic distributor
Y68.2. Pneumatic cylinder splices two papers. Free ends of the paper are cut by knives. The holder (3) is
released and turns to non-working position. The change of the old bobbin with a new one is completed. The
electrical motor M30.5 leading the acceleration roller (2) stops. In assigned lower speed of splicing, after the
splicing is done the machine will accelerate till the production speed, after blowing of the agglutinated section
of the paper (When bobbin change occurs, splicing is done in a lower speed).
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
6.4.10.2 Speed for performing change of the bobbins
(fig.17)
Control panel display
The program allows machine speed to be set to use during bobbins change procedure. This can be done on
screen “3. Operator Setup – General” on the main control panel (1). Machine is working on the lower speed
(speed for splicing) until filter with agglutinated section of the paper is blown away. After this, machine
accelerates to production speed.
It is recommended the change of the bobbins to be performed in the maximal

production speed (100%), for the purpose of constant quality of the filter rod.
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
6.4.10.3 Splice and ejection

PV80.2 1 PV80.3
PV80.3
3
2
(fig.18)
Splice and ejection
After the splicing of the old paper band with the new one, tracking of the agglutinated section by the control
system /PLC/ begins. It is necessary, for the elimination of the filter rod later with the agglutinated section on
the fluted drum (1). Throwing is operated by pneumatic distributors Y10.4 and Y10.6.
It is necessary the filter rod with the agglutinated section of the paper to be thrown
on the fluted drum.
Preliminarily condition for throwing the splice

In order to be assured throwing exactly of the filter with paper seam, the following conditions must be fulfilled:
It has to be precisely adjusted the tact of cutting of the timing disk,
It has to be calculated correctly the distance that the paper passes from the splicing device to the blowing the
first filters of the V-way.
The distance differs when there is format change of the machine. It has to be calculated and set into the control
panel MP277
Calculating the distance for ejecting the splice

To calculate the distance from the splicing device (3) (the holder of the splicing band) to the blowing the first
filters of the V-way (2), do the following:
Stretch filter paper between these two assemblies, mark the paper against the air vent of the outgoing rim and
against the holder of the splicing band.
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
Calculating the distance for ejecting the splice
To calculate the distance from the splicing device (3) (the holder of the splicing band) to the blowing the first
filters of the V-way (2), do the following:
Stretch filter paper between these two assemblies, mark the paper against the air vent of the outgoing rim and
against the holder of the splicing band.
After that remove the filter paper and the measured distance from marker to marker has to be entered in
the field “Splicing point to V-way” (in mm) on screen “4.1.11 Technical setup – RMM – Sampling” on the control
panel touch screen of the Rod Module. It also has to be reported and the distance between the outgoing rim and
the fluted drum.You have to measure it and to enter it in analogous way.
You have to set up and the rest of the parameters on the control panel touch screen of Rod Module, as the
PLC to be able to perform throwing on the place with splicing, i.e. enter the length of the produced filter rods,
enter a number of filter rods for throwing – on screen “4.1.11 Technical setup – RMM – Sampling” in the field
“Rejected per splice”.
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
6.5 Gluing process

6.5.1 Process description
The process of laying the glue strips on the paper is performed of glue nozzles. It is recommended for splicing
the seam to be used hot melt glue, and for splicing the filter segments to the paper cold glue (PVA).
The glue nozzles (3, 4, and 5) lay on the paper two, three or four strips of glue, in accordance to the customer
requirements. Disperse glue nozzles for inner gluing may be installed on the machine (depend on the customer
requirements and brand specification). Using this kind of nozzles you can adjust width of glue stripe. This can
be done by moving nozzle toward or backward to the paper. Often on the Rod Module there are contact
nozzles installed.
7
s
3 (fig.19)
6
Glue system
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D000138675
Rev. 02; 05.07.2018
6.5.2 Glue tank and nozzles
The feeding of the nozzles with glue is performed with the aid of two different tanks – one for hot melt glue
(2) and one for cold glue (1).
The cold glue (PVA) from the tank (1) enters into the magnetic operated pumps (7). From the pump the glue is
carried to the nozzle (4, 5) depending on the speed of the filter rod.
According to the customer requirements there might be two nozzles for cold glue – in this case one (4) is – used
for the seam, and the other one (5) – for internal splicing.
Hot melt glue is used to lay the side seam. The tank (2) is filled with granules of glue. It is liquefied through
heaters in the tank and the chamber and is prepared for feeding to the nozzles (3) and (6) through a heated
hose. The carrying of the liquefied glue from the chamber to the nozzle is performed by pumps. The quantity
of the glue depends on the speed of the filter rod.
The machine is not ready for operation, until the temperature in all zones with hot
melt glue does not reach the assigned minimal values.
Applying the hot melt glue

The process of laying the hot melt glue on the seam of the filter rod is automatic and it goes under the
following conditions:
 The heaters are switched on – faceplate button

The temperature has reached the minimally assigned value – service screens “4.1.2 Service Data
Temperature – Seam”, “4.1.3 Service Data Temperature – Inner”.
Set Test glue flow rate on screens “4.1.4 Hot Melt Seam”; “4.1.5 Hot Melt Inner” – S 86.3
The machine is started.
 Starting position for laying the glue is reached:

The electrical motor M32.3 is turning on,
The glue pump supercharges the hot glue to the nozzle,
It is switching the distributor Y78.3 and the nozzle passes glue for the seam.
 Stopping the glue feed. Glue feed stops in the following scenarios:
In usual stop of the machine,
In break-down stop,
In test mode without materials - S120.4/S86.2/,
Switch S86.3 in left position – does not allow passing of the glue.
 Cleaning the glue pump for hot melt glue
In case you have to clean the glue pump when it is still heated use cleaning agents with flash point over
280°С. When the glue pump needs cleaning use liquid paraffin to clean it.
When fitting the pump be careful not to allow grease to enter the pump since
this may cause problems with the seaming of the filter rod
After fitting the pump, check if it will rotate freely when heated - to do that, turn manually the pump a couple
of times.
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
Applying the PVA glue for seam and inner gluing of the filter segments
PVA glue feed start.
The process of passing the glue is performed when:

Set PVA glue in start mode – screen “3.5 Operator setup – Gluing”
6.5.3 Start the machine
The stepper drive for cold glue is actuated, it creates the necessary pressure to transport the glue to the glue
nozzle. When activated, the distributive block for glue nozzles of cold glue and the nozzles passed the glue
for the seam and for the internal splicing
Glue feed stop
The laying of the glue for inner gluing turned out in stopping the machine, by analogy of the hot melt glue
stopping.
(fig.20)
 Calibration of the hot melt glue quantity fed.
Calibration sequence of the hot melt glue:

Enter the consumption of hot melt glue on the control panel display (fig.20) - screens “4.1.4 Hot Melt – Seam”;
“4.1.5 Hot Melt – Inner”.
Turn the switch S86.3 for passing the glue in right direction,
The glue is passed on with the production speed for the chosen by you time,
Measure the actual quantity of glue, (measure the weight),
Compare the assigned and the measured quantity of glue,
Enter the coefficient of correction and repeat the calibration,
The glue feed is calibrated when the weighted quantity of glue and the entered value are equal.
Example:
Enter a value for glue quantity 8 m3/min,
Release glue for 1 min and measure the weight
The measured quantity must be 8 m3/min,
If necessary make a correction of the coefficient until quantity becomes 8.
AIGER CONFIDENTIAL
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Rev. 02; 05.07.2018
 Calibration of the PVA glue quantity fed
The process of passing the glue is performed when:

Set the machine is in stop mode,
Set PVA glue in stop mode on the display – faceplate button .

Enter the consumption of PVA glue on the display (fig.20) – screens “4.1.6 PVA Seam Gluing”; “4.1.7 PVA Inner
Gluing”,
Enter Calibration time on the display (fig.20) - screens “4.1.6 PVA Seam Gluing”; “4.1.7 PVA Inner Gluing”.
 Start calibration with soft key – “Calibration” ,

It is turned on the operation of the stepper drive for cold glue,
It is supercharged the glue to the glue nozzle,
It is switched on the distributive block for glue nozzles of cold glue and the nozzles passed the glue for the
seam and for the internal splicing,
The glue feed is calibrated when the weighted quantity of glue and the entered value are equal.
Settings of the nozzles for laying the glue
(fig.21)
Glue nozzles
The passing and stopping of glue from the nozzles is performed with the help of the needle (1). The pin is
moved from the compressed air for closing and opening, coming from connector (2).
 Glue feed
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Rev. 02; 05.07.2018
When is given the start for laying the glue, the compressed air is passed to the needle and it moves the pin
to the right. It is overcame the spring power in the nozzle and the pin touches the back cap (3). The feeding
of the nozzle with glue is completed through a knee (4).
 Glue feed stop

The supply of compressed air is terminated in stopping the glue feed. The spring is released and it moves
the needle forward and it closes the nozzle.
Glue feed
For detailed process description see section 6.5.1 Process description.

The feeding of the nozzles with glue is performed from two different tanks – for hot melt glue (1) and for
cold glue (2).
The cold glue (PVA) from the tank enters into the magnetic operated pumps. From the pump the glue is carried
to the nozzle (2, 5) depending on the speed of the filter rod.
According to the customer requirements there might be two nozzles for cold glue – in this case the one (2) is –
used for the seam, and the other (5) – for internal splicing.
The machine is equipped with three glue nozzles:
One for the seam with hot melt glue (1),
One for the seam with cold glue (2),
One for the inner glue with cold glue (5).
To set the nozzles do the following:
Install the nozzles perpendicularly to the paper
Bring the nozzles closer as much as possible to the paper (to do this rotate handles 3 and 6),
Adjust the hot melt glue nozzle (1) to apply the glue at the end of the paper,
Adjust nozzle (2) to the desired place for laying the glue on the side seam through the handle (4),
Adjust nozzle (5) to the desired place for laying the glue for inner gluing through a handle (7).
Side seam glue nozzles (1 and 2) are linked and can be adjusted simultaneously (1). Once the relative position
of the nozzles is set, there is no need to be adjusted again
3
4
5
6
7
1
(fig.22)
Mechanical settings of the glue nozzles
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
The glue nozzles are adjusted toward the paper in two planes, in order to be received the desired glue
applying.
Sequence of the setting the position of the nozzles toward the paper
To set the nozzles do the following:
Install the nozzles perpendicularly to the paper
Bring the nozzle closer as much as possible to the paper (to do this rotate handle 3),
Adjust the hot melt glue nozzle (2) to apply the glue at the inner of the paper (rotate the handle (4)),
The position of the glue strips can be changed only by the handle (4). Rotating the handle on clockwise direction
– moves glue strips toward machine. Rotating the handle on counter clockwise direction – move strips toward
the paper end.
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
6.6 Forming the filter rod

6.6.1 Stages of forming the filter rod
1 S58.3 2 4 5
3 6
(fig.23)
 Tow supply
The tow is supplied by a transport jet (5) from the upstream machine AIGER FLEX TOM to the garniture tongue
(4).
The paper with the glue on it, and the prepared tow enter the format garniture (6). In the format garniture
they form an uninterrupted filter rod, which is transported by the garniture tape. The paper is wrapping
around the tow and is sealed by a rod forming sealing chamber (3).
The machine is supplied with the pre-requested by the client format garniture
specifications.
Garniture tongue
The garniture tongue forms the tow supplied by the AIGER FLEX TOM in a rod. The garniture tongue should be
periodically inspected for wearing out at its front end. In case of such wear it should be replaced and adjusted.
 Format garniture body
The format garniture together with the cover rails and the sealing chamber (3) form an uninterrupted filter
rod. The filter rod is gradually formed when passing through the following sub-assemblies.
Sealing the filter rod
Through the sealing chamber (3) it is possible to make slight adjustments in the filter rod diameter (+/-0,1mm)
at the moment of its sealing.
Cutting off the filter rod
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
The automatic rod cut off unit (2) cuts the rod in the beginning of the process of filter rod forming. The rod is
cut so that it can automatically enter the diameter-measuring nozzle (1).
 Filter rod control
A passive filter rod control is carried by an optic sensor (SN58.3), prior to the diameter-measuring nozzle (1).
6.6.2 Garniture tongue adjustment procedure (steps)
3 6
2
7
1
(fig.24)
Garniture tongue adjustment procedure (steps)
When replacing or adjusting the garniture tongue, the following steps should be observed:
1. Tighten the garniture tongue (1) to the holder (6) by using the screws (2)
2. Take off the covering rails (3)
3. Loosen the screws (5) and adjust the garniture tongueit in such way that it should be right in the center of
the format garniture, after that tighten the screws (5)
4. By using screw (7) adjust the front end of the garniture tongue, in such a way that it lays 10-12 mm
insinde the covering rails (3). Tighten screw (7) in place by using stop screw (8)
5. Adjust the hight of the front end of the garniture tongue in such a way thet between it and the covering
rails (3), 2 layers of filter paper can pass freely. Tighten the screws (2).
Adjust the garniture tongue only with a new garniture tape.
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
Garniture tongue adjustment procedure
1/ The height of the garniture

tongue in the front side so that:
- Two layers paper must pass
free between the garniture
tongue and the folding
section.
2/ The height in the rear side:
- With placed garniture
tongue four layers paper
must pass between the tape
and the garniture tongue.
(fig.24.1)
3/ The garniture tongue goes under
the folding channels. The
recommended distance has to be
10÷12 mm.
4/ ATTENTION!
The edge must be not pressed to
the surface A.
(fig.24.2)
With help of the finger stop the
bullet roller under the garniture
tongue (the machine must be in
working mode). For correct
adjustment the paper goes only
straight, i.e. not forward or
backward, as shown with the red
arrow.
(fig.24.3)
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
6.6.3 Garniture tape drum

The garniture tape (4) is driven by a garniture tape drum (5). The speed of the garniture tape is equal to the
speed of the filter paper.
1 4 5 3
S66.2
2
(fig.25)
Garniture tape drum
The garniture tape is automatically tensioned by a pneumatic cylinder (1) that acts on the tensioning roller (3)
of the garniture tape drum (5).
The pneumatic cylinder (1) is controlled by a switch (2). For further information refer to AIGER FLEX TOM
Operation manual, Chapter 5.Control panels.
When the switch (pos. 2 – S62.2, fig.25) is turned to the right – the supply of compressed air is stopped and
the garniture tape is loosened.
When the switch (2) is turned to the left – the supply of compressed air is resumed and the garniture tape is
tensioned.
Loosen the garniture tape (4), when the machine will not be used for a long period
of time. This will increase the life of the garniture tape.
To maintain constant optimal tensioning force to the garniture tape, air pressure that is supplied to the
pneumatic cylinder (1) has to be about 3 bars.
The outer diameter of the garniture drum together with the transport band should be 223 mm.
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
6.6.4 Garniture tape

The garniture tape (1) carries the filter paper with the tow rod inside it through the rod forming sealing
chamber (2) and the format garniture (3). There the filter rod is formed. The garniture tape is driven by the
1
garniture tape drum (4). Its position, toward garniture center is controlled by a guide roller (5).
2 1
4 5
(fig.26)
Garniture tape
Garniture tape sizes

In our standard configuration we install the standard series of garniture tapes from Esband:
NKO 43 – for hot melt glue,
SAO 77 – for cold glue,
SKP 46.2. – for hot melt glue and with porous paper.
The length of the garniture tape for AIGER FLEX RMM is 2715 mm.
The width of the garniture tape depends on the circumference of the filter rod. To
calculate the width of the garniture tape you must apply this formula:
Garniture tape width [mm] = Circumference of the filter rod [mm] minus 6 mm.
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
Example:
Circumference of the filter rod = 21,98mm
Garniture tape width = (21,98 – 6)mm = 15,98 mm (approx. ± 0,5 mm)
Garniture tape width ≈ 16 mm
Table of the format range of the format garniture, the filter paper and the garniture tape
Format Format garniture Garniture tape width Filter rod Filter paper width
(mm) range (mm) (mm) circumference (mm) (mm)
D 6.0 6.0-6.09 14.0 18.85 20.5

D 6.1 6.1-6.19 14.0 19.16 20.5
D 6.2 6.2-6.29 14.5 19.48 21.0
D 6.3 6.3-6.39 14.5 19.79 21.0
D 6.4 6.4-6.49 14.5 20.11 21.0
D 6.5 6.5-6.59 15.0 20.42 22.0
D 6.6 6.6-6.69 15.0 20.73 22.0
D 6.7 6.7-6.79 15.0 21.05 22.5
D 6.8 6.8-6.89 15.0 21.36 23.0
D 6.9 6.9-6.99 15.0 21.68 23.0
D 7.0 7.0-7.09 16.0 21.99 23.5
D 7.1 7.1-7.19 16.0 22.30 24.0
D 7.2 7.2-7.29 16.0 22.62 25.0
D 7.3 7.3-7.39 17.0 22.93 25.0
D 7.4 7.4-7.49 17.0 23.25 25.5
D 7.5 7.5-7.59 17.5 23.56 25.5
D 7.6 7.6-7.69 17.5 23.87 25.5
D 7.7 7.7-7.79 17.5 24.19 26.5
D 7.8 7.8-7.89 18.5 24.50 26.5
D 7.9 7.9-7.99 19.0 24.82 27.0
D 8.0 8.0-8.09 19.0 25.13 27.0
D 8.1 8.1-8.19 19.5 25.44 27.0
D 8.2 8.2-8.29 19.5 25.76 28.0
D 8.3 8.3-8.39 20.0 26.07 28.0
D 8.4 8.4-8.49 20.5 26.39 28.5
D 8.5 8.5-8.59 20.5 26.70 28.5
D 8.6 8.6-8.69 20.5 27.02 28.5
D 8.7 8.7-8.79 20.5 27.33 29.5
D 8.8 8.8-8.89 21.0 27.64 29.5
D 8.9 8.9-8.99 21.5 27.96 30.5
D 9.0 9.0-9.09 21.5 28.27 30.5
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
6.6.4.1 Garniture tape adjustments
2 1 3
7 6 8 9 5
(fig.27)
Garniture tape adjustments
The garniture tape is adjusted by a roller guide (5). The adjustment can be done through a handle (6).
When the handle is turned clockwise – the garniture tape moves toward the operator.
When the handle is turned counter-clockwise – the garniture tape moves away from the operator and closer
to the machine.
The garniture tape must be changed once it wears out. The garniture tape wears out when:
Starts to drive irregularly the filter rod,
The edges of the garniture tape start to brake,
There are problems with the quality of the filters – the wearing has direct impact on the diameter of the filters
- filter diameter out of range.
6.6.4.2 Garniture tape change

To change the garniture tape you must do the following steps:
Lift the rod forming sealing chamber (3) to its upper position,
Loosen the screw (2) on the cover (1) of the format garniture and remove the cover,
Remove the handle (7) and the garniture tongue (8), and transport jet (9)
Loosen the garniture tape through switch (S66.2 on TOM machine),
Remove the old garniture tape.
Place a new garniture tape and centralize it on the garniture tape drum.
Place back the garniture tongue (8) and the cover (1).
The direction for placing a garniture tape is indicated by an arrow. Place the
garniture tape only in the indicated direction
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
6.6.5 Sealing the filter rod

The filter rod is formed and sealed in the format garniture (1) and the rod forming sealing chamber (2).
2 3
(fig.28)
Sealing the filter rod
In order to seal properly the filter rod the glue (hot melt glue) on the paper must be in heated condition
before entering the sealing chamber. This is done to prevent the glue from solidifying before the filter rod is
wrapped. Once the continuous filter rod is wrapped in the format garniture, the sealing is cooled. The cooling
bar is situated inside the sealing chamber (2). Format garniture is also cooled by the format garniture bed
(4). The cooling on these two places is done to ensure proper sealing of the filter rod even on the high speed.
Sealing chamber (2)

When hot melt glue is used the sealing chamber (2) is cooled to seal the filter rod. The cooling liquid is supplied
from the cooling tower.
Format garniture support (4)

The format garniture bed (4) can be additionally cooled when hot melt glue is used. In this case another cooling
circle is needed for the format garniture support beside the one for the sealing chamber. The cooling unit is
and option.
Check weekly the condition of the sealing chamber and particularly the cooling bar for wearing out. If
necessary replace the cooling bar with a new one to ensure proper sealing of the filter rod.
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
6.6.6 Automatic rod formation with sealing chamber (Cooling bar)
Automatic rod formation

with sealing chamber
(Cooling bar)
This section outlines the adjustments to be carried out on the cooling bar.
Before carrying out procedures remove the front cover of the cooling bar by loosening the mounting screws (as
illustrated below):
remove
Fig. 29
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
6.6.6.1 Cooling bar to format garniture guides
1. Lower the cooling bar by operating on the HMI

touch-display of the machine.
2. The distance between the cooling bar (pos.1) and the format garniture guides (pos.2) is required to be at
least 2 mm.
1 2
>2 mm
Cooling bar (open position) Cooling bar (closed position)

Fig. 30
3. When the correct distance is set, tighten the 3 screws (pos.3) to fix the position.
Fig. 31
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
6.6.6.2 Cooling bar seating onto the format garniture

1. Adjust back supports (pos.1) and front supports (pos.2) so that when lowered the cooling bar is seated
seamlessly and centered onto the format garniture.
Fig. 32
2. Adjusting the shifting action of the cooling bar
The hinges of the pneumatic mechanism holds the cooling bar on spring-loaded plates (pos.2), therefore the whole
cooling bar construction can nudge or shift when lowered and seated onto the format garniture.
Shorten or extend the length of the pneumatic cylinder rod (pos.1) until the distance between plate (pos.2) and
the spring blocks (pos.3) is 4 – 5 mm (recommended) – as illustrated below.
4–5 mm 2
1
Fig. 33
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
6.6.6.3 Adjusting filter rod diameter

First, level out the arms (pos.1) until parallel to garniture bed (pos.4).
Tighten the four screws (pos.2) until they touch their seats (pos.3) on the garniture bed (pos.3). Regulate the height
provided that:
Height at the entrance is 38.2 mm (A) and at the exit – 38.0 mm (B). The distance is measured from the top of
the garniture bed to the top of the cooling bar.
In this position tighten the locking nuts of the screws (pos.2).
Once the adjustment is completed fit the cover of the cooling bar back on, start the machine and use handle
(pos.5) to adjust the filter rod diameter (or the stepper motor – option).
5
2
B A
4 3
Fig. 34
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
6.6.7 Filter rod heating
The temperature settings are recommended by the company manufacturer of the glue.
Every heating unit is activated from the MP277 control panel on the AIGER FLEX RMM machine.
(fig.35)
Switching on and off the heating is done through faceplate button on the control panel.
The heating units operate on the following basis:
A thermal sensor measures the temperature of the heater.
A temperature regulator compares the measured real temperature with the one pre-set from the MP277
display – screens 4.1.2 Service Data Temperature – Seam; 4.1.3 Service Data Temperature - Inner.
If the real measured temperature is lower than the pre-set the heater is switched on.
For every heating unit there should be a temperature input in the process diagram displayed on MP277 on
the AIGER RM PRIFLEX RMM machine – – screens 4.1.2 Service Data Temperature – Seam; 4.1.3 Service Data
Temperature - Inner. The following parameters are input in service mode:
Minimal heating temperature allowing machine start,
Pre-set temperature input for every heating unit,
Maximum heating temperature.
Hot glue will not be supplied before every heating unit reaches its minimal pre-
set temperature.
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
6.6.8 Filter rod cooling

A cooling liquid is supplied by the cooling tower (1), to the filter rod forming chamber (2). It is used to seal
the filer rod when hot glue is used.
(fig.36)
Filter rod cooling
There are different types of cooling circles depending on the design and construction of the machine. For
better sealing on high speed, as an option the format garniture bed is also cooled (2).
Setting up the required working temperature is done in service mode on of the control panel display of the
AIGER FLEX RMM machine.
The real temperature of the cooling liquid of the filter rod forming chamber is monitored on screen “4.1.2
Service data temperature – seam” and “4.1.3 Service data temperature – inner” of the control display of
the AIGER FLEX RMM machine.
For the recommended settings of the cooling temperature see Chapter 5 “Control Panels”.
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
3
2
S12.2
S58.3 5
1 4
(fig. 37)
Rod cut-off device
The purpose of the rod severing device (4) is to cut-off and automatically inserts the filter rod into the diameter
control nozzle (1).
It is pneumatically operated and controlled by opening and closing the safety cover (2). When the safety
cover (2) is closed, a safety sensor (S12.2) sends an activation signal to the pneumatic distributor (Y12.3),
which allows the activations of the filter rod cut-off unit (4). This unit sends control signal to the pneumatic
cylinder through pneumatic distributor. The cylinder turns the cutting head towards the filter rod movement
direction and closes the scissors (5) to cut-off the filter rod.
After cut-off the end is immediately disposed of and a continuous rod is inserted in the diameter control nozzle
(1). The machine will accelerate to production speed when sensor S58.3 registers the presence of a filter rod.
When the safety cover is opened (2) the cutting head moves backwards and the scissors (5) open.
Settings
The speed of the cutting head back and forth is controlled through reducing the airflow from restrictor of the
pneumatic distributor-Y78.8. The movement of the cutting head in both directions should be smooth. When
turning the restrictor clockwise the speed is reduced and when turning it anti-clockwise the speed is increased.
The safety sensor S12.2 should get activated, when the distance between the electromagnets of the two
halves of safety sensor (S12.2) is less than 5 - 10 mm.
The distance between the guide (3) and the filter rod at closed cover (2) should be adjusted to about 0,5 mm
Eliminating the safety devices may result in serious injuries.
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
6.7 Cut-off unit
5
2
1 3
(fig.38)
Cut-off unit
Filter rod cut-off is one of the most important processes performed by Rod module. The purpose of this process
is to cut off filters with exact length and without damaging their ends.
The filter rod cut-off is done by a knife unit that consists of:
Ledger holder (1) – the knife (2) that cuts off the filters passes between the cutting ledgers (8). The cutting
ledgers themselves (8) are fixed onto the ledger holder, and it is mounted on two leaf springs. Their movement
is synchronized with the movement of the knife carrier (6), through an arm (3);
Knife carrier (6) with knives (2) – the knife carrier is a rotating balanced body, which is driven by the main
motor and a series of gears. Two knives are placed on it and with every turn they cut two filters out of the
continuous filter rod;
Grinding drives (5) – next to the knife carrier (6) are placed two motors (5), on which are mounted the
sharpening disks. Their purpose is to sharpen the knives (2) on the carrier. The disks are so placed that the knife
(2) touches them on every turn. On every turn of the knife carrier (6) the knives (2) get sharpened;
Safety sensor (7) – The entire knife carrier is covered with a safety cover, which is locked with a safety sensor
(7). The purpose is to protect the operating personnel and to prevent opening of the cover while the machine
is running.
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
6.7.1 Instruments and gauges for setting the filter way
3
7
1
4
2
5
6
(fig.38.1)
Instruments and gauges for setting the filter way
Pos. Item Name

1 Stud set
2 Filter rod gauge
3 Knife advance adjustment gauge
4 Cut-off bearing gauge
5 Socket wrench
6 Brush
7 Rotary wrench
8 Wrench
9 Vacuum gauge
For the proper installation and adjustments of the sub-assemblies on the filter way we use the following
instruments and gauge:
Control pressure foot gauge (1).
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
6.7.2 Straight filter way adjustment
(fig.39)
Straight filter way adjustment
The procedure for proper installation and adjustments of the sub-assemblies to ensure straight filter way is as
follows:
Installation and adjustments of the ledger holder on the leaf springs (2),
Installation and adjustments of the cutting ledger tubes (3),
Installation and adjustments of the diameter control nozzle (4),
Installation and adjustments of the V-way (1).
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
6.7.3 Ledger holder

Function description
2 1
1
4
(fig.40)
Ledger holder
During the cutting process the filter rod is guided by two cutting ledger tubes (2) mounted on the ledger
holder (1). The knife passes between the cutting ledgers (2) and cuts off the filter rod. The ledger holder (1)
is mounted on leaf springs (3) and is driven through a connection rod by the arm (4).
Adjustments of the ledger holder and the leaf springs in accordance with the filter rod and the format
garniture
To level the ledger holder (1) you need the following gauges:
Ledger holder gauge;
Straight filter way gauge,
Vertical ledger holder gauge.
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
6.7.4 Installing and adjusting the ledger holder
2 А B
1
2 4 3
5
(fig.41)
Adjusting the ledger holder and the leaf springs
To adjust the ledger holder you must follow these steps:

Remove the guide rollers of the format garniture and the guide rollers of the filter paper;
Remove the format garniture upper guides;
Remove the control nozzle (5);
Remove the counterweight (3) from the eccentric (4);
After you mount the gauge connect it to the ledger holder (1);
Slightly loosen all locking screws on the ledger holder (1) and the leaf springs (2);
Place in the format garniture support gauge (B), push it left and insert the axle in the opening on gauge (A).
In this position fix gauge (B) with the locking screws on the format garniture support. Once you do this tighten
all screws on the ledger holder and the leaf springs.
To make easier the final fine-tuning, on the base of the machine can be mounted a
measuring indicator with the help of a magnetic stand. The indicator must be
mounted sideway on gauge (A), which is fitted to the ledger holder.
Adjustments verification
Adjustments verification of the ledger holder is done the following way:
Slightly loosen the locking screws on the ledger holder (1) and the leaf springs (2);
Loosen the screws on the format garniture support and by moving gauge (B) back and forth, check the
adjustments of the ledger holder. The axles of gauge (B) should freely enter the opening on gauge (A);
The deviations shown by the indicator must not exceed 0,02 mm. If these deviations are greater the ledger
holder must be levelled again;
Verify again the adjustments; Remove all gauges.
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
6.7.5 Installation of the arm
6
1
5
7 4
(fig.42)
Installation of the arm mechanism
The arm of the ledger holder is installed on the machine the following way:
Attach counterweight (1) on the eccentric (5)
To be observed the condition for proper installation of the counterweight – when

the counterweight is in up-right position, the arm must be in down position!
Mount the arm (4) on the eccentric (5);

Check the needle-roller bearing of the arm (4);
Mount the axle (2) on the arm (4) to connect the ledger holder (6) with the eccentric (5), and then fix the
axle (2) with two locking screws.
The needle-roller bearing should be greased with the axle grease pump (2) each
8 working hours.
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
6.7.6 Installing and adjusting of the guide tube
(Fig. 43)
Guide tube
To adjust the guide tube, follow the outlined steps below:
Remove the format garniture so that you can insert the straight filter way gauge (pos.1). Place the gauge in the
format garniture bed, and insert it through the inlet guide (pos.2) of the optical measuring device.
Insert further to the left to reach the guide tube (pos.3) and have it adjusted so that the gauge moves freely
through the inlet guide (pos.2). When achieved, fix the position of the guide tube (pos.3) with screws.
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
6.7.7 Installing and adjusting the diameter control nozzle
3
1
(fig.44)
Installing the control nozzle
To install and adjust the control nozzle you:

Straight filter way gauge (2),
To install and adjust the control nozzle you must follow these steps:
Remove the format garniture upper guides so that you can insert the straight filter way gauge,
Loosen the screws on the control nozzle (2) and the ones on the body it is attached to;
Fix the control nozzle, so that the gauge (1) to enter the axle of the straight filters way and move freely back
and forth;
Check the adjustments once all screws are tightened.
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
6.7.8 Adjusting the cutting ledger tubes
1 2 3 4 5 6 2 4 7
Х 8
(fig.45)
Adjusting the cutting ledger tubes
The distance “Х” between the cutting ledger tubes (2 and 4) must be equal to the thickness of the knife (3)
plus 0,05mm.
To adjust the cutting ledger tubes (2 and 4), turn the knife carrier in such way that one of the knives (3) to be
in position for cutting.
Then loosen the locking screws (1 and 5) on the ledger holder (6).
Cutting ledger inner tube
Drive the cutting ledger (4) close to the knife without forcing it so that the knife (3) won’t bend;
Tighten the screw (5).
Cutting ledger outer tube
Place between the cutting ledger (2) and the knife (3) two times folded filter paper or a plank with thickness
approximately 0,05 mm:
Slightly press the cutting ledger to the paper and tighten the screws (1);
Pull out the paper.
Adjusting the knife movement between the cutting ledger tubes
To adjust the knife movement between the cutting ledger tubes for all filter lengths the following prerequisites
must be met:
During the cutting the knives (3) must pass between the cutting ledges and parallel to the cutting plain of the
ledgers (2 and 4),
On their way the knives (3) must slightly touch the ledger inner tube, but they should not bend.
Maintenance
The sides of the cutting ledger tubes (2 and 4) that have contact with the knives (3) must be inspected (when
working 2 shifts) weekly for wear and tear. If the sides are worn out the cutting ledger tubes must be replaced
and the knives settings should be checked.
AIGER CONFIDENTIAL
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Rev. 02; 05.07.2018
If you change the filter length you must also change the counterweight. The guide
tube also has several versions depending on the filter length range and it might
need replacing as well.
6.7.9 Adjusting the cutting ledger stroke at different filter length
Every time you change the filter length you must also adjust the cutting ledgers move.
This can be done primary through the scale on the body (5). Then the fine-tuning can be done by measuring
the actual cutting ledger tubes movement with a gauge or calliper.
3 1
5
(fig.46)
Adjusting the cutting ledger tubes move
Primary adjustments
Primary adjustments are made according to the scale printed on the side of the body (1). This scale represents
different filter lengths. To do the adjustments you must do the following steps:
Loosen the six screws (3) on the body (1);
Turn the body (1) so that the required filter length from the scale to match the sign on the disk (2);
Tighten the screws on the body.
Fine-tuning is not possible by only using the scale on the body, (1). For fine-tuning certain measurements must
be made with a gauge or calliper.
Fine-tuning
The fine-tuning is made by measuring the cutting ledger tubes movement from left end point to right end
point. Using the handle turn the knife carrier (4) to measure the ledger holder movement (5). If the result
differs from the ones in the following table than you must return to primary adjustments from the body. The
ledger holder move may vary but not more than 0,05 mm. For these settings you can use electronic calliper.
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
Table of the ledger holder move
Ledger holder Ledger holder Ledger holder

Filter length Filter length Filter length
movement movement movement
60 18,89 90 27,87 120 36,55

62 19,50 92 28,46 122 37,12
64 20,10 94 29,05 124 37,69
66 20,71 96 29,63 126 38,25
68 21,31 98 30,22 128 38,81
70 21,92 100 30,80 130 39,38
72 22,52 102 31,38 132 39,94
74 23,12 104 31,96 134 40,50
76 23,72 106 32,54 136 41,06
78 24,32 108 33,12 138 41,61
80 24,91 110 33,69 140 42,17
82 25,51 112 34,27 142 42,72
84 26,10 114 34,84 144 43,27
86 26,69 116 35,41 146 43,83
88 27,28 118 35,98 148 44,38
150 44,93
Balancing the knife carrier
The knife carrier for filter rod cut-off is dynamically balanced. The knife carrier should be dismantled only
for repairs. After the repairs are made you should check the balance and re-balance the knife carrier if
necessary. We recommend that you always keep a spare knife carrier on stock.
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
6.7.10 Installing the knife carrier
1 2
(fig.47)
Installing the knife carrier
The knife carrier (1) is a balanced rotating body with two knives (4) that cut the filter rod. The knife carrier
movement is synchronized with the ledger holder movement.
To install the knife carrier you must follow these steps:

Attach the knife carrier (1) to the reduction gear shaft, and fix it by tightening the screws;
Place the cutting ledger tubes in central position. The body mechanism must be in such position that the
counterweight to be in up-right position and the arm in down position. When the knife carrier is turned forward
the filter rod should move forward too and the cutting ledger tubes should move left. Turn the knife carrier until
it reaches cutting position. Then tighten the screws;
Place and adjust the bearing support (3) using gauge.
Place the two knives (4) in their places on the knife carrier;
Set the knife way through the cutting ledger tubes.
6.7.10.1 Technical maintenance of the knife holders

The knife holders are greased through four grease nipples that are hidden behind cover (5) of the knife carrier
(1). You should be careful not to tear the seal between the cover and the knife carrier body.
(fig.48)
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
Every time you change the length of the filters you must adjust the movement of the cutting ledger tubes,
and the passing of the knives between them.
6.7.11 Adjusting the filter rod cutting
(fig.49)
Adjusting the filter rod cutting
To adjust the cutting to be in the middle of the filter rod (9) you must follow these steps:
Measure the move of the cutting ledger tubes;
Slowly turn the knife carrier (fig. 49) in the spinning direction and stop when the ledger holder is half way
the cutting ledger tubes move, and moving in the same direction as the filter rod;
Block the main motor;
Turn of the air supply to the machine;
Slightly loosen the screws that hold the knife carrier and turn it until one of the two knives (5) gets in cutting
position;
The blade edge of the knife (5) must be between the cutting ledger tubes and above the centre of the filter
rod (9);
Tighten the screws;
Restore the main electro and air supply to the machine.
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
6.7.12 Adjusting the angle of the knife carrier
2 3
(fig.50)
Adjusting the angle of the knife carrier
Every time you change the length of the filters you must also adjust the angle of the knife carrier (1). To do
this loosen the screws (3) and turn the frame:
For filters with shorter length the frame should be turned clockwise;
For filters with longer length – counter clockwise.
When you change the angle of the knife carrier the bearing support (7) to the
carrier should be released.
To install the knife carrier you must follow these steps:

Loosen the cutting ledger tubes and pull them aside to ensure maximum space between them;
Remove the knife advance pneumatic cylinder
Place gauge in the bearing support (7);
Loosen the four screws (3) on the drive frame and the two screws on the support;
Turn the knife carrier and observe the passing of the knives in front of the cutting ledger inner tube;
After every turn of the drive frame, move the support (7) so that the gauge (5) can move freely;
Keep adjusting until the knives start to move parallel to the front surface of the cutting ledger;
Tighten the screws on the drive frame (2) and on the support (7).
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
6.7.13 Knife sharpening
1 2 1
(fig.51)
Knife sharpening mechanism
When you work in the knife carrier zone there is always a danger of injuries even
when the machine is stopped and the safety brackets are on.
To achieve a perfect cut from each knife they should be constantly sharpened. The standard length of the
knife is 108 mm. During the production process, the knife advance lever drives the knife forward after a given
number of filters cut (the number can be adjusted from the control panel). Before you mount new knives you
must check:
If there is grease or any other impurities on the knives
If the blades are sharp
To place a new knife, press the pin (2) with a screwdriver. The distance between the cutting blade and the
knife holder “Х” must be 18-19mm.
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
6.7.14 Automatic knife advance unit

For the automatic knife advance to function properly the following values should be inputted through TP277
(screen 4.1.10):
The number of filter cuts after which the knife should be driven forward;
The number of advances after which a warning message for knife change is displayed on the main control
display;
The number of advances after which if the knife is not changed the machine will stop and the error message will
be displayed.
1 2
1
(fig.52)
Knife sharpening mechanism
The pneumatic cylinder (3) moves an axel that triggers the knife advance in the knife carrier (5) (see 6.7.15
Operation of the knife advancing mechanism). The two knives should advance equally at the same time.
The two knives advance (1) can be checked by pressing manually the pneumatic cylinder (3) 20 times – this
way the knives will be driven forward 20 times. Measure how much each knife has advanced from the starting
position. If we assume that each advance moves the knife (1) forward with 0,06mm, than in 20 advances the
knife must be out by 1,2mm.
If there is pressure between the knife and the sharpening disk, it means that
the angle of approach is too small.
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
6.7.15 Adjustment of the knife advancing mechanism

When the pneumatic knife advancing unit is actuated, the end of the pusher (pos.1) presses on the contact end
of two levers (pos.2). On the lever there is a strip (pos.3) that transfers the motion to the gear wheel (pos.4).
Another strip (pos.5), mounted on the housing of the mechanism, stops the turning of the wheel.
When turned the gear wheel (pos.4) carries the motion via a shaft to the next mechanism, which in its turn ejects
the knife.
2
1
5
4
Fig. 53
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
Adjusting the ratchet mechanism strips:
The ratchet strips (pos.1 and pos.2) are adjusted so that when the pneumatic pusher is actuated once (presses
once the lever end (pos.3)), the gear wheel (pos.1) moves exactly one tooth.
This is achieved by loosening the screws (pos.5 and pos.6) and adjusting the position of the actuating strip (pos.1)
and the stopping strip (pos.2).
Repeat the adjustment until the result is achieved.
4
3
1
Fig. 54
When both ratchet mechanisms are adjusted, test the knife advance function by manually pressing the pneumatic
pusher 50 times.
If the adjustment is correct, after 50 knife advances, both knifes are ejected at equal lengths, as illustrated on
fig.55. Repeat the test 3 – 4 times to confirm the results.
A=B
Recommended setting:
After 50 knife advances the ejected

knife length should be 2.4 – 2.6 mm.
B
Fig. 55
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
6.7.16 Knife sharpening
M6.5
2
1
3
M6.4
(fig.56)
Knife sharpening
The sharpening mechanism consists of sharpener drives (M6) that are mounted with screws onto the arm (2).
Sharpening disks
The sharpening disks (1) should be checked every two shifts for wear and contamination. If it is necessary to
clean the disks (1) remove them and clean them with a brush and ethyl alcohol. The sharpener drives М6.4
and M6.5 start to work at the same time as the main drive.
Adjusting the sharpening mechanism

The adjustment of the sharpening mechanism depends on the filter length. Every time you make changes on
the knife carrier you have to also check the sharpening disks settings.
The sharpening disks (1) should have slight contact with the knives down the entire length of the blade. This
can be achieved by turning the drives holders (3). First adjust sharpening disk (1), and the other.
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
6.7.17 Adjusting the sharpening disks angle
(fig.57)
Adjusting the sharpening disks angle
To adjust the sharpening disks angle you must follow these steps:
The arm (11) of the mechanisms (9 and 12) is centralized by screws (10),
Loosen the screws (10) and change the angle of the arm (11), so that it corresponds to the filter length settings;
Tighten the screws (10).
The described below adjustments may influence the previous adjustments you
made!
Every time you change the filter length in order to maintain the perfect sharpening down the entire length of
the blade you have to move arm (11) back or forth.
Direction K – shorter filter;
Direction L – longer filter.
Adjusting sharpening disk (17.1)
Loosen screw (15.1) and adjust the angle through adjusting screw (14.1). Through (14.1) the sharpening disk
is rotating around axis (E), and it sharpens down the entire length of the blade.
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
(fig.58)
Adjusting the sharpening disks angle
Adjusting sharpening disk (17)
Loosen screw (15), and through adjusting screw (14) turn the sharpening disk around axis (E).
Adjust the angle so that the knife blade passes down its entire length through a sharpening disk.
Adjusting the sharpening disks in accordance with the knife carrier
Turning the sharpening disks in direction A or B, try to:
Front sharpening disk – try to set the distance between the knife carrier and the tip of the sharpening disk to
1-2mm;
Rear sharpening disk - try to set the distance between the knife carrier and the tip of the sharpening disk to
3-4mm;
Adjusting the sharpening disks in accordance with the knives
The knives should extend 18-19mm from the knife carrier (5). To adjust the sharpening disks you must follow
these steps:
Loosen screws (16 – 16.1).
Adjust the distances of the sharpening disks using the adjusting screws (13 – 13.1) in direction (C – D), to
achieve sharpening down the entire length of the blade.
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
6.7.18 Knife carrier safety cover
S14.3
(fig.59)
Knife carrier safety cover
Even when the machine is not operational and the safety brackets are on there
is danger of injuries when you work with the safety cover opened.
The knife unit consists of different mechanisms than move with high speeds when the machine is operational. If
a person from the servicing personnel stays near the knife unit when the machine is working at high speed he
might sustain heavy injuries. For this reason the knife unit is covered with a safety cover (1). When the machine
is operational the cover is controlled and locked by a safety sensor S14.3. The machine cannot start unless
the safety sensor S14.3 detects closed cover and is locked.
After the machine stops the cover is unlocked when the following conditions are met:
The PLC receives a signal that the machine has stopped. This signal is generated by safety relay K8.2; (A)
certain period is passed (2-3 sec.).
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
6.8 Filters acceleration
1 2
Ejection hole
From cutting
(fig.60)
Exit Rod module
After the filters are cut they are transported to the fluted drum (1) by a double accelerator (2). They are
transported down a V-way with a grove for filter ejection at machine start or stop.
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
V-way
6 4
4
(fig.61)
Adjusting the V-way
6.8.1 Function
After the filter is cut, it is pushed through the cutting ledger outer tube by the next filter towards the V-way
(4). On the v-way the filter is hold up by a brush (1).
At machine start or stop some filters from the V-way are ejected so to keep only the quality product. This is
done sideway through a grove (6) by a pneumatic distributor Y68.1.
The distance ‘X’ between the brush (1) and the v-way must be approximately:
Х ~ filter diameter - 0,1- 0,2mm.
Adjusting the V-way
The V-way must be vertically and horizontally positioned in accordance with the way the cutting ledger tubes
position the filters. The adjustments are done with a cylindrical gauge. To adjust the v-way you must follow
these steps:
The level of the V-way should be slightly below the level of the cutting ledger tubes,
The level of the V-way should be slightly above the fluted drum channels – 0,1-0,5 mm,
The V-way must be parallel to the machine frame,
There should be a distance of 165 mm from the ejection wholes to the fluted drum.
When the pneumatic distributor (Y68.1) ejects filters they enter a chute (2), which transports them to the waste
bin.
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
6.8.2 Double accelerator

3
(fig.62)
The acceleration rollers on the exit
The double accelerator is designed to separate the cut filters and to insert them into the fluted drum (4). To
do this the two acceleration rollers (1) have higher peripheral speed than the speed of the produced filters.
The acceleration rollers are driven by a servo drive M28.5. The speed of the acceleration rollers can be
adjusted by the main control display of Rod Module and it is dependent of the filter length.
 Adjusting the rollers

The distance between the two rollers (1) should be equal to the filter diameter minus 0,2 – 0,4mm (position C
on Fig 62 left). The adjusting is done through a screw (3):
Turn the screw (3) clockwise – the two rollers get closer;
Turn the screw (3) counter-clockwise – the two rollers are separated.
When the distance is too small or too big this prevents the optimal acceleration
of the produced filters.
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D000138675
Rev. 02; 05.07.2018
 Adjusting the height of the acceleration rollers
(fig.63)
Adjusting the acceleration rollers
To adjust the height of the acceleration roller you must follow these steps:
Remove the belt (1);
Loosen the screws (2) and remove the main arm;
Place or remove shims, to adjust the height of the arm;
Place the arm and the belt back.
Tight the screws (2).
Double accelerator speed settings
(fig.64)
The speed of the double accelerator is changing proportionally to the speed of the main motor. It is set from
the control display (fig.67) – “4.1.1 Technical setup – RMM – Drives settings – RMM”.
At start up the speed of the double accelerator is always greater than the set percentage in field “Acc. Over
speed” on screen 4.1.1.
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
6.8.3 Filters transfer

1 1
(fig.65)
Fluted drum
When the accelerator rollers accelerate the filters they enter the fluted drum, (1). In it the filters are decelerated
and positioned in order through a vacuum. From the fluted drum the filters are send to a transfer drum and then
with a transport belt to the next machine.
Double acceleration rollers belt pre-tension
Double acceleration
Unit
rollers
Catalogue number of
174977
belt
TF-10 B 10mm L
Type of belt
650mm
Length of measured
240
stand [m]
belt [Hz] 48
min
max 60
Pre-tension [N] 40
ATTENTION! The measurement position is always at the longest part of the belt
drive between 2 pulleys. Calculation are based on measurement with Trummeter
produced by Hilger u. Kern GmbH
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
6.8.4 Fluted drum

When filters enter the fluted drum (1) they must stop at a distance of about 5-10 mm and then align by the
stops at the end of the fluted drum groves.
(fig.66)
Adjusting the vacuum of the fluted drum
The gentle stop of the filters in the fluted drum channels is done through a vacuum. A valve with a handle (1)
on the cover regulates the vacuum:
When you operate the handle forward you reduce the vacuum and the stopping force on the filters;
When you operate the handle backward you increase the vacuum and the stopping force on the filters.
The vacuum can be changed and by changing the revolutions of the fan. The recommended speed of the fan
is 90% of the maximum speed of the motor.
Fluted drum cleaning
The vacuum holes on the fluted drum should be cleaned manually at least once a shift. The cleaning is done
by blowing compressed air into the openings.
The automatic cleaning of the fluted drum groves is done through distributor PV80.1.
Fluted drum gear box
The fluted and the transfer drum as well as the link up to the next machine are drive by a series of gears. All
gears are enclosed in a gear box that is filled with 3 kg of grease. The gear box doesn’t require additional
greasing. During repairs or once every 4000 working hour you should change the grease and apply a thin
layer of oil to all metal parts to protect them from corrosion.
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
6.8.5 Producing a filter rod for fluted drum adjustments
(fig.67)
To produce a continuous filter rod for setting the catching in the menu on the control panel display (fig.69) -
screen “4.1 Technical Setup – RMM”. Follow the steps outlined below:
The machine should be in automatic regime– turn on from faceplate button ,,

Input starting speed (field “Startup speed”) – we recommend 200 filters/min,
Input production speed (field “Production”) – we recommend 50 filters/min,
Start the machine and produce a continuous filter rod,
Monitor the catching and stop when the filter is at a minimal distance from the fluted drum.
The program is designed to start the machine at start up speed (field “Startup speed”) and then when the set
number of filters is produced the machine will slow down to the minimal production speed 50 filter/min. At this
speed stop the machine at the needed moment to adjust the fluted drum.
The machine can be also stopped from a normal stop button on the control panel or from a right green button
from the wet and dry samples control panel (in service regime it functions as a normal stop button).
The program is designed to switch to automatic regime after one minute of

service regime in order to protect the drives from running for a long time at
such low speeds.
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
6.8.6 Table of parameters for setting the catching
To set up the catching you must calculate distances depending on the filter length.
The distance (D) depends on the filter length (L) and the speed of the double accelerator. In the table below
you can find the recommended values for these parameters.
(fig.68)
Catching parameters
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
6.8.7 Transfer drum

9 6 7 8 2 10
11 12 A 7 1
13
(fig.69)
Transfer drum and output transport
The transfer drum (11) should be adjusted in accordance with the fluted drum (9), so that the groves of the
two drums may coincide in the point of transfer of the filters. The groves of the drums must be exactly opposite
to each other in the point of transfer.
Settings
The transfer drum is adjusted after you loosen the two locking screws (13);
In the point of transfer there should be no vacuum in the channels on both drums;
The distance (A) between the flange (12) and the transfer drum, should be 0,2 – 0,4mm.
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
6.8.8 Output transport
Process description
After transfer drum, the filters move between upper (pos.2 fig.71) and lower (pos.1 fig.71) transport belts of
the output transport. In case of filter flow jam the upper belt moves up and actuates S72.4 sensor which triggers
a line stop.
S72.4
S72.4
(fig.69.1)
Rod module – output overload
Adjustment
Distance between upper and lower transport belt must be set so as the “X” dimension to be equal to filter
diameter minus 0.1mm.
X = I – 0.1 [mm]
Upper and lower belts are tensioned through tensioning rollers so as not to allow the belt to skid around the
rollers.
Distance “X” adjustment at the exit (10) – loosen the screws (7) and the upper belt transmission starts spinning
around the main axis until roller (10) reaches desired distance “X”. The screws (7) are to be tightened
afterwards.
Distance “X” adjustment at the entrance (6) – loosen or tighten the setscrew (8) until both belts are parallel.
Technical maintenance
Remove and clear the drums and grease gently all metal parts each 2000 working hours.
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
6.8.9 Antistatic bar
U6.6
(fig.70)
Antistatic
The antistatic bar (U6.6) is used to remove the static charge of the filters down their entire length.
Antistatic positioning
The antistatic should be positioned exactly over the filters when they pass from the catcher to the transfer
drum.
Cleaning
The antistatic (U6.6) should be cleaned with compressed air one or twice a week.
When you clean the antistatic bar you must switch off the machine’s supply. There
should be no electricity current.
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
6.8.10 Filter ejection
Y10.4 Y10.6
Y80.7
Y80.5
(fig.71)
Filter ejection
Rod module is equipped with 4 fast reacting pneumatic valves. The function of these valves is to eject filters
from the fluted drum (1) and the V-way.
Reasons for filter ejection:
Ejecting the first filters form the fluted drum (1) – Y10.4 and Y10.6 at machine start;
Ejecting the last filters from the fluted drum (1) – Y10.4 and Y10.6 at machine stop;
Taking dry/wet samples from the fluted drum (1) – Y80.5 and Y80.7;
Taking dry/wet samples from the fluted drum (1) – Y80.5 and Y80.7;
Filter ejection from fluted drum (1) – Y10.4 and Y10.6 at splice.
The ejected filters from the V-way are dropped down a chute into the waste bin.
The ejected filters from the fluted drum (1), are dropped down a chute (4) into a waste bin, placed under
the drums.
Filter ejection at machine start
When the static filter rod control registers the presence of filter rod, pneumatic valve P68.1 on the V-way
ejects a certain number of filters. The number of filters to be ejected is set from the control panel of the
machine. After the first filters are ejected the machine enters production regime.
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
Y10.4 Y10.6
Y80.7
Y80.5
(fig.72)
Filter ejection
6.8.10.1 Filter ejection at machine stop
When the machine stops all filters are ejected on the V-way. When the machine has entered start/stop
program all filters are ejected from the fluted drum by pneumatic valves Y10.4 and Y10.6. This happens
when:
The stop button of the main drive is pressed;
An error message has appeared on the main control display of the Rod module
The number of filters to be ejected during start/stop program is set from the main
control panel.
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
6.8.10.2 Filter ejection at bobbin splice

A splice occurs when the two bobbins (old and new one) are attached to each other with a double adhesive
scotch band. The filters with splice on them must be ejected. In the machine program there is a function that
monitors the splice and ejects a certain number of filters.
Dry and wet sample (optional)
Y10.4 Y10.6 4 3
Y80.7
Y80.5
(fig.73)
Filter ejection
For test purposes, wet (with plasticizer) and dry (without plasticizer) samples can be taken from the fluted
drum and gathered in a box (4). The filters are then measured and tested with specific devices.
The wet and dry samples are ejected through pneumatic valves Y80.5 and Y80.7 from the fluted drum.
All settings for ejecting filters and taking samples are made from the main control
display of Rod module
(Check screen 4.11 Technical setup – TOM – Sampling).
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
6.9 Lubrication system
HEATED OIL
COOLED OIL
(fig.74)
Lubrication system
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
The Rod module has a lubrication system with constant flow of oil that lubricates the following assemblies:
(fig.74)
- Main drive shaft: bevel gear set, rear bearing;
- Knife head: distributor for knife head drive;
- Arm for tube folder;
6.9.1 Function of the lubrication system

The function of the lubrication system is to supply lubricant (oil) with the required flow, temperature and
pressure to lubricate the bearings and the gears and in the same time facilitate the cooling and the normal
functioning of the mostly used assemblies.
The oil from the oil tank (1) is sucked by an oil pump (2) (gear type) and through oil filter (3) is supplied to
oil cooler (4). The purpose of the filter (3) is to keep the oil clean from mechanical particles. The oil cooler
(4) reduces the temperature of the oil to the required one. The temperature range for normal oil work is 60-
65ºC. After the oil radiator the oil way is divided – separated tubes run to the bevel gear set and an oil
distributor (5). The oil distributor supplies oil to the rear bearing, arm for the tube folder and knife head
drive. The working pressure of the oil is monitored by pressure sensor S72.6 that receives signals from the oil
distributor. This sensor is part of the main drive control system. The sensor controls the oil pressure, when the
pressure is under 1.0 bars it submits a signal for machine operation stopping.
For further information refer to chapter 5. Control panels.
During production if the pressure is below 1.0 bar the sensor circuit opens and the
machine stops. An error message is displayed: OIL PRESSURE TOO LOW -S72.6,
see 5.2 Operating messages.
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
6.9.2 Oil change

After 1000 working hours you must change the oil and the oil filter. For further information refer to chapter
7.2 Maintenance plans and 7.3 General points of lubrication.
For Rod module with central oil system the quantity of transmission oil is 6-7 litters.
Manufacturer Brand Viscosity in mm2/с Point of Point of

ignition in °C liquefaction in °C
in 40°С in 100°С
SHELL OMALA 150 22 >250 -30
150
(fig.75)
Oil level indicator
6.9.3 Oil fill
Remove the cap of the main gearbox and fill it with oil until the oil lever on its back is covered to the red
line of the glass indicator. (fig.77)
Start the secondary drives and wait about 5-10minutes. Turn off the secondary drives. After 3 minutes check
the oil level and if necessary add oil,
Close the main gearbox with the cap.
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
6.10 Pneumatic system

6.10.1 Description of the pneumatic systems
The pneumatic system of the Rod module machine is divided in several levels and the functioning mechanism
on each level require different air pressure and has different consumption. For further information about the
parts of the pneumatic system refer to the spare parts catalogue.
(fig.76)
Pneumatic system
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
The entry pressure of the compressed air is controlled by two pressure switches:
For the Rod module – it is set to start the supply at 3,5 bar and to switch it off when below 3 bar.
Compressed air feed lines

The compressed air that enters the pneumatic system is divided down 11 feed lines
Garniture tape tensioner

The executive mechanism of the garniture tape tensioner is a pneumatic cylinder. In the feed line is mounted
a regulator) that reduces the pressure to 3 bar. To ensure the proper functioning of the cylinder it is
supplied with oiled air.
Bobbin changer plate lock

The executive mechanism of the bobbin changer plate lock is a pneumatic cylinder working with oiled air.
The speed of reaction is controlled through restrictors.
Rod severer
The rod severer is controlled by a double action pneumatic cylinder working with oiled air. The speed of
reaction is controlled through restrictors-silencers.
Fluted drum
The fluted drum uses non-oiled air for cleaning and ejection of filters and samples.
Transfer drum
The transfer drum uses non-oiled air for cleaning.
Splice cut-off (paper cut off)

The executive mechanism is a single acting pneumatic cylinder working with oiled air.
Glue system
The glue nozzles are supplied with oiled air.
V-way
A non-oiled air is used for filter ejection at start/stop of the machine.
Diameter control unit

The diameter control unit is supplied with non-oiled air that additionally passes through a delicate micro-
filter. The compressed air is controlled by a regulator that is set to 2.5-3 bar.
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
6.10.2 Pneumatic group
4
1
2 3
(fig.77)
Pneumatic group
The supplied compressed air for the Rod module enters the pneumatic group through an orifice (1) with a
condense filter (2). The condense filter (2) removes the mechanical particles and the moisture from the entering
compressed air.
The pressure is reduced by a pressure regulator (3) to 5 bar, and then it passes through a pressure switch (4).
Technical maintenance
The condensation from the filter (2) is drained automatically but you should check and clean the filter every
300 working hours. The filter is cleaned with soap water and after 2000 working hours you must replace it
to prevent moisture from entering the pneumatic group.
Do not use cleaning agent that contain chlorine or alcohol!
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
6.11 Cooling system
AIGER CONFIDENTIAL
D000138675
Rev. 02; 05.07.2018
Highway Parameter settings Picture

2.1 Entrance -
2.2 Main drive 2
2.3 Oil cooler 6
2.4 Drum drive 2
2.5 Cooling electrical plate 1
2.6 Cooling format garniture full open
AIGER CONFIDENTIAL
D000138676
D000138676 Maintenance
Rev. 06; 26.09.2018
7 Maintenance .................................................................................................7.2
7.1 Preface ......................................................................................................7.2
7.1.1 Chapter objective ............................................................................................... 7.2
7.1.2 Chapter purpose................................................................................................. 7.2
7.1.3 Safety instructions for technical maintenance ................................................ 7.2
7.2 Cleaning....................................................................................................7.3
7.3 Overview of maintenance work...............................................................7.4
7.4 Maintenance plans ...................................................................................7.5
7.5 General points of lubrication ..................................................................7.16
7.6 Hotmelt unit maintenance.......................................................................7.18
7.6.1 Washing the filter............................................................................................ 7.19
7.6.2 Replacing the filter .......................................................................................... 7.19
7.6.3 Cleaning agents ............................................................................................... 7.20
7.6.4 Conditional cleaning periods ......................................................................... 7.20
7.6.5 Full cleaning ...................................................................................................... 7.21
7.6.6 Heavy deposits in the tank............................................................................. 7.25
7.6.7 Flushing the heated hoses ............................................................................... 7.26
7.7 Maintenance preservation directions......................................................7.27
7.8 Troubleshooting ......................................................................................7.28
AIGER CONFIDENTIAL
D000138676
Rev. 06; 26.09.2018
7 Maintenance
7.1 Preface
- Cleaning of the machine
- Maintenance plans
- Lubrication
- Troubleshooting

- Maintenance staff
- Service staff
7.1.3 Safety instructions for technical maintenance

Strictly follow the instructions and requirements for safety in your factory as well as the instructions and
requirements described in Chapter 2 – “Safety” of this Operational Manual.
Technical maintenance periods

The technical maintenance periods are described in this TM Schedule. They are based on 7,5 work hours per
shift.
AIGER CONFIDENTIAL
D000138676
Rev. 06; 26.09.2018
7.2 Cleaning
After the machine has been stopped a number of handled materials still remain inside. It is recommended to
empty and clean the machine prior to a lengthy shutdown period – at the end of a work shift. Perform it as
follows:
- Stop the machine – press button “Stop” and switch off the main supply’
- Stop the supply of compressed air;
- Remove the available materials from the machine;
- After the emptying the machine, perform cleaning with compressed air and dry towel.
For further information see chapter 2. Safety.
AIGER CONFIDENTIAL
D000138676
Rev. 06; 26.09.2018
7.3 Overview of maintenance work

The following table provides general guidance for maintenance and cleaning of Rod Maker Module. For detailed
description of the machine zones and their maintenance plans please see 7.4 Maintenance plans.
Hours operated Maintenance and lubrication

7.5 a) Clean the filter screen of the cooling blower;
b) Clean out dust and glue from the machine;
c) Inject grease into the crank drive nipple.
15 a) Check the garniture tape guide rollers and the paper travel rollers for
free running;
b) Check the sickle knives in the cut-off, replace them if necessary;
c) Check knife advance;
d) Check diamond grinding wheels, clean them if necessary;
e) Clean glue from cutting ledgers, V-way and fluted drum.
75 a) Check all rollers, sprocket wheels etc..
300 a) Grease the four nipples on the knife carrier;
b) Check all toothed, flat and V-belts for wear and make sure they are
correctly tensioned; replace as necessary;
c) Check rubber rollers on the bobbin changeover system for ease of
movement, replace bearings if necessary.
1000 a) Change the oil and the oil filter in the circulating system. All subsequent
oil changes every 4000 hours operation;
b) Check the disc brake lining of the bobbin changer for wear out;
c) Check rubber rollers on pairs of rollers in tensioning zone for signs.
2000 a) Check operation of the main switch after every major maintenance, setup
or repair operation.
4000 a) Check that the earthing conductors are firmly secured;
b) Check that the EMERGENCY STOP system is working properly.
Hours operated Maintenance and lubrication

If required Replace the filter of the air pressure supply.
Replace boots on pneumatic cylinder.
Replace brake linings.
Check glue seam pump; check inner gluing pump; clean system.
Check garniture tongue.
Check and change garniture tape coating if necessary.
Check Sikora measuring system.
AIGER CONFIDENTIAL
D000138676
Rev. 06; 26.09.2018
7.4 Maintenance plans
Task Description Maintenance section Action End of day

No /every 7.5
h/
1. Leading rollers of the Clean up from paper
garniture tape; dust and glue with
Leading paper rollers compressed air and
wet cloth.
2. Sharpening disks and Clean with alcohol Do

knife-sharpening not use wired brush
device and benzenes.
3. Ledger bearings Grease with 1 cm3

grease.
4. Ledger holder Clean the tubes with

metal brush.
Check the level of
wearing out of the
tubes and replace
them with new, if
necessary.
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Rev. 06; 26.09.2018
5. Garniture tape Check on every shift

for wearing out and
tearing and replace if
necessary.
6. AC filter Clean the AC filter.
Because of differences in working conditions, the operation hours specified herein below
should be considered as tentative. The quantity of operation hours is subject to
adaptation and minimum change.
AIGER CONFIDENTIAL
D000138676
Rev. 06; 26.09.2018
The 15 hours maintenance plan includes maintenance of all machine sections described above along with the
following:
Task Description Maintenance Action End of

No section two days
/every
15 h/
1. Entire machine Clean up with vacuum cleaner
and compressed air.
2. Rod forming Clean from glue

chamber and contamination with wet cloth.
guide plates Check the level of wearing out
of the garniture tape, replace
if necessary.
3. Knife advance Check the operation.

unit
4. V-way Clean the V-Way from glue

contamination with wet cloth
or compressed air.
Sikora Clean the Sikora diameter

Diameter control device with dry air.
control device
AIGER CONFIDENTIAL
D000138676
Rev. 06; 26.09.2018
Fluted drum Clean the fluted drum with

compressed air or wet cloth
Because of differences in working conditions, the operation hours specified herein

below should be considered as tentative. The quantity of operation hours is subject
to adaptation and minimum change.
AIGER CONFIDENTIAL
D000138676
Rev. 06; 26.09.2018
following:
Task Description Maintenance Action Every 75h

No section
1. Garniture tongue  Check the settings
and adjust, if
necessary.
 Check the level of
wearing out and
replace it with new,
if necessary
2. Cooling system Clean the filter.
3. Cover strips of the Check the level of

garniture wearing out and
replace it with new, if
necessary.
4. Antistatic of the Clean with com-

fluted drum pressed air and soft
brush.
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D000138676
Rev. 06; 26.09.2018
5. Filter rod transfer Clean with com-

pressed air
6. Transfer drum Clean the flutes of the

drum from filter
contaminations with
compressed air.
7. Air filters Clean with vacuum

cleaner.
8. Area of the main Clean with vacuum

operation cleaner.
9. Pneumatic group Clean the moisture

filter.
AIGER CONFIDENTIAL
D000138676
Rev. 06; 26.09.2018
following:
Task Description Maintenance section Action Every

No 300h
1. Knife holders of the knife Grease 1 cm3 over each
head (the four greasers) point.
2. Rollers of the splicing Clean from

mechanism contamination, Check
for easily spinning and
clean/replace the
bearings, if necessary.
3. Main drive belt Belts Check the stretching

and the level of
wearing out; replace
them, if necessary.
Swiveling plate belt
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D000138676
Rev. 06; 26.09.2018
Double accelerator belt
Output transfer belts
4. Pneumatic cylinders Check for normal

operation.
5. Electric cabinets Clean with vacuum

cleaner.
6. Garniture drum tape Check regularly the

level of wearing out
and replace it with new,
if necessary.
AIGER CONFIDENTIAL
D000138676
Rev. 06; 26.09.2018
7. Hot melt system See Chapter 7.5 Hot

melt unit maintenance
8. Paper splicing unit Check the rubber rollers

of splicing device – if
worn out, replace them.
AIGER CONFIDENTIAL
D000138676
Rev. 06; 26.09.2018
The 1000 hours maintenance plan includes maintenance of all machine sections described above along with
the following:

No 1000h
1. Oil system Replace the oil and oil
filter of the oil system.
Next changes need to
be done on every
4000 working hours.
Prevention for safety operation!

After 1000 working hours it is necessary to replace the leaf springs of the tube
holder.
The 2000 hours maintenance plan includes maintenance of all machine sections described above along with
the following:

No 2000h
1. Filter rod transfer Dismantle and clean the
drums of the filter rod
transfer. After the
cleaning lightly grease
all the metal parts.
AIGER CONFIDENTIAL
D000138676
Rev. 06; 26.09.2018
The 4000 hours maintenance plan includes all machine sections described above along with the following:
Task Description Maintenance Action Every

No section 4000h
1. Oil system Change the oil and the oil
filter of the oil system.
2. Filter rod transfer Check quantity and the

condition of the grease of the
fluted drum gear box and
apply new grease, if
necessary.
Task Description Maintenance section Action If

No necessary
1. Glue pump for hot melt Clean the pump
system
AIGER CONFIDENTIAL
D000138676
Rev. 06; 26.09.2018
7.5 General points of lubrication
1 2 3 4
Greasing points
Nr Description Greasing
1 Gearbox of the leading filter rod transfer Grease
2 Knife holder of the knife head Grease
3 Ledger bearings Grease
4 Central oil system Transmission oil
AIGER CONFIDENTIAL
D000138676
Rev. 06; 26.09.2018
Transmission oil
The quantity of transmission oil required for a machine RMM with central oil system is 6-7 liters.
Manufacturer Brand Viscosity in mm2/с Point of Point of

ignition in °C liquefaction in
in 40°С in 100°С °C
FUCHS CASSIDA 150 18,9 >268 -54

150 GL
Grease for the crank drive bearings and for the knife holders in the knife head
Manufacturer Brand NLGI Penetration in Working Drop

grade 25°С-0, 1 mm temperature range temperature
in °C in °C
Kluber Straburags 1 260 -20…+150/+170 >+200

NBU 12
AIGER CONFIDENTIAL
D000138676
Rev. 06; 26.09.2018
7.6 Hotmelt unit maintenance

Deposits in the hotmelt unit are the most frequent reason for failures. Therefore, the entire system must be kept
clean at all times and it is very important that the maintenance tasks described below are carried out.
If the tasks are not carried out or are not carried out correctly, then malfunctions
such as blockages may occur. Malfunctions of this type do not usually follow a
regular pattern and are often difficult to localize.
The maintenance intervals apply to one-shift operation. If the system is being used more heavily than this, the
frequency with which maintenance tasks are performed will need to be increased accordingly.
Period Task How

Rinsing out the filter to remove Rinse out any impurities using the drainage plug;
impurities see Chapter 7.4.1, "Washing the filter".
Check all screw fittings on the distributor block,
heated hoses and application heads for
Visual check of screw fittings
escaping hot melt. Replace any screw fittings that
Weekly are not tight.
Check all power cables, connecting cables, the
pneumatic hose and the heated hoses for signs of
Visual check of cables and hoses
external damage. Replace damaged cables or
hoses.
Check the coarse filter in the tank for deposits.
Visual check of coarse filter Remove any impurities from the coarse filter and
Monthly tank; see Chapter 7.4.3, "Cleaning the system".
Cleaning the tank lid Clean the tank lid using cleaning oil.
Twice a year
or Replacing the filter See Chapter 7.4.2, "Replacing the filter"
message "A90"
Yearly
or Flush and clean the entire hot melt
See Chapter 7.4.3, "Cleaning the system"
message "A91" system
AIGER CONFIDENTIAL
D000138676
Rev. 06; 26.09.2018
7.6.1 Washing the filter

Rinse any accumulated adhesive impurities on the filter out of the drain opening. The filter does not need to be
removed for this purpose. Condition: The device has reached the operating temperature.
 Set the pressure regulator on the piston pump

to 0 bar.
 Place a temperature-resistant container under
the drain opening (1) on the distributor block.
 Open the drainage plug (2). Hot melt will flow
out of the drain opening (1).
 Increase the pump pressure and keep draining
the hot melt until you can no longer see any
impurities flowing out of the drain opening.
 Close the drainage plug again. Replace the
filter cartridge if it is heavily soiled.
(Draining impurities)
7.6.2 Replacing the filter

Condition: The device has reached the operating temperature. The tank must not be empty.
 Set the pump pressure on the regulator to 0 bar.
 Discharge the system pressure. To do this, place a temperature-resistant container under the drain opening
(1) on the distributor block. Open the drainage plug (2) until hot melt starts flowing out. When it stops
flowing out, this means the system pressure has been reduced. Leave the drainage plug (2) open.
 Remove the screw plug (3). The filter cartridge

is still fixed in the bore hole.
 Screw an M5 screw (5) or the special filter key
into the thread of the filter cartridge (4) and
pull the filter cartridge (4) together with the O-
ring (6) out of the bore hole.
 Clean the bore hole using fibre-free cleaning
material and push the new filter cartridge
together with the O-ring into the bore hole.
 Screw the screw plug (3) back in tightly.
 Once the filter has been replaced, there will be
air in the system. Increase the pump pressure
slightly so that the air can escape from the
drain opening (1). As soon as only hot melt is
escaping from the drain opening, close the
drainage plug (2). The device is ready for
operation again. (Replacing the filter cartridge)
AIGER CONFIDENTIAL
D000138676
Rev. 06; 26.09.2018
7.6.3 Cleaning agents
Only use cleaning oil to clean the tank.

Only use the cleaning oil in the tank: never pump it through the entire system. Using
it in the heated hoses and head may result in clumps that could remain even after
full cleaning has been carried out.
Never use cleaning agents containing solvents, such as nitrocellulose combination

thinner, acetone, and so on. There is a risk of fire if these agents come into contact
with hot parts.
The cleaning agent must have a high flash point and must be non-toxic at the
processing temperature. It must not create a chemical reaction with the adhesive or
device parts and must not have a corrosive or otherwise damaging effect on device
parts.
7.6.4 Conditional cleaning periods

Below are outlined the conditional cleaning periods in accordance with utilization of the unit and/or
troubleshooting cases.
The amount of oil required to clean a machine depends on the size of the gluing unit (5L, 8L, 12L etc.) and the
degree of contamination with burned glue, and other materials that can reach into the unit.
The cleaning frequency of units is as follows:
Machine utilization/Case Cleaning frequency

8 hours/day 1 time per 1 year
24 hours/day Every 6 months
When contamination with foreign materials occur All the time
When glue type is changed All the time
Problems that indicate a clogged system All the time
The quantity of oil necessary to clean small parts (nozzle, filter, screw) is depends on the size / capacity of the
heating pot and the amount of parts that are to be cleaned, (and the employee who is cleaning the pieces).
The cleaning agent must have a high flash point and must be non-toxic at the
processing temperature. It must not create a chemical reaction with the adhesive or
device parts and must not have a corrosive or otherwise damaging effect on device
parts.
AIGER CONFIDENTIAL
D000138676
Rev. 06; 26.09.2018
7.6.5 Full cleaning

The entire hot melt system must be fully cleaned and flushed at least once a year. More frequent cleaning may
be required depending on the circumstances described below:
The frequency with which internal cleaning needs to be performed in the device
depends on the processing temperature, the thermostability of the hot melt, and the
material quantity that is processed. The shorter the throughput time and the lower
the processing temperature, the lower the risk of deposits in the tank and of
malfunctions occurring as a result.
During cleaning work, it is essential that you wear

clothing that covers the arms and legs as well as
heat-resistant gloves and protective goggles.
Conditions
– The adhesive melter is switched on and has reached the operating temperature.
– The necessary tools, cleaning agents, spare glue filter and O-rings are available to hand.
– Around half a day has been set aside for the work.
1. Distributor block
2. Drain bolt
3. Drain opening
4. Filter screw
AIGER CONFIDENTIAL
D000138676
Rev. 06; 26.09.2018
1. Relieve the system pressure

 Note the shown air pressure on the manometer of the piston
pump Set the pressure controller at the piston pump back to 0
bar.
 Place a temperature-resistant container under the drain
opening (3) at the distributor block
 Open the drain bolt (2). Hot hotmelt will now flow from the drain
opening (3)
It may happen that the drain screw is blocked, i.e. that no adhesive emerges at
all. In this case the glue pressure must be relieved by switching on the applicator
heads.Replace the complete drain cock immediately. Further operation is not
allowed with a defective drain cock!
2. Remove the adhesive filter at distributor block

 Place a temperature-resistant container under the filter opening
(4) at the distributor block.
 Remove the screw plug (4). The filter cartridge is still seated in
the bore.
 Screw an M5 bolt or the special filter key into the thread of the
filter cartridge (5) and pull the filter cartridge (5) including the
O-ring from the bore.
 A sinter filter can’t be cleaned. It has to be replaced. Mesh filter
might be cleaned in hot cleaning oil or must be replaced.
 Replace the seal ring of the screw plug (4).
 Use high temperature grease for the screw plug.
 Screw the screw plug (4) without the filter back in again.
3. Empty the tank

 Open the drain bolt (2).
 Increase the pressure at the pressure regulator of the pump to 0.5…1.0 bar until the adhesive flows
continuously out of the drain opening (3).
 Set the pressure at the pressure regulator of the pump back to 0 bar or remove the air supply.
 Activate temperature lowering (ca. 100 °C)
AIGER CONFIDENTIAL
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Rev. 06; 26.09.2018
4. Remove the pump

 Remove the pump and clean it using rags free of fluff.
 Replace the O-ring at the foot of the pump and apply silicone grease to
it.
5. Clean the tank lid and the cover

 If the cover is heavily contaminated, remove the lid and clean the area.
6. Remove deposits in the tank

 Remove the coarse filter (grid) and clean it.
 Remove residues of adhesive in the tank with a wooden scraper and rags
free of fluff.
7. Insert the pump again

 Use high temperature grease for the thread of the pump and insert the pump
and tighten it.
8. Special cleaning of the tank in case of heavy deposits

 Heavy deposits in the tank can be softened with cleaning oil. For normal cleaning the cleaning oil is not
an absolute necessity.
9. Fill the tank with new adhesive

 Fit the filter screw plug (4) (without filter) again.
 Close drain bolt (2).
 Fill the tank with new adhesive and let it heat up to working temperature.
 During the melting process one can already remove the nozzles at the applicator heads and clean them
(see point 12).
10. Flush the tank after cleaning

 Open the drain bolt (2).
 Increase the pressure at the pressure regulator of the pump to 0.5…1.0 bar o more mixture of dirt, oil
and adhesive emerges.
11. Special cleaning of the heated hoses

 Heavy deposits in the heated hoses can be removed by flushing the hoses under pressure. For this purpose
the adhesive or the cleaning agent recommended by the supplier is made more viscous by a reduction of
the operating temperature. This procedure can not guarantee a complete charring free core of the hose.
12. Clean the applicator heads

 Drain the glue pressure by manual activating of the applicator heads on the
pattern controller or directly on the valve (B).
 Unscrew the nozzles from the heads and clean them. Clean the bores with nozzle
needles and scrape them using a small scraper/knife (from tip away). Replace
the nozzles if necessary.
 If necessary place nozzles in hot cleaning oil, then blow them out with compressed
air. Eventually use special tools.
 Clean the applicator heads from the outside using the spatula or wire brush.
AIGER CONFIDENTIAL
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Rev. 06; 26.09.2018
13. Remove filter in applicator heads (if any)

 Remove the filter screw plug at the applicator head.
 Pull out the filter cartridge using the M5 filter spanner.
 Replace the O-ring seal at the screw plug.
 Leave the filter bore in opened condition.
 Do this for each applicator head …
14. Check the jetting element for leakage

 If adhesive is visible in the leakage bore (C), replace the jetting element or exchange
the sealings.
15. Flush the system

Note: The applicator heads can be flushed individually or together.
 Place a temperature-resistant receptacle under the filter bore of the applicator heads.
 Close drain bolt (2).
 Increase the pressure at the pressure regulator of the pump to 0.5…1.0 bar until the adhesive flows
continuously out of the filter bore of the applicator heads.
 Fit the filter screw plug (without filter) at the applicator head again temporarily.
 Increase the pressure at the pressure regulator of the pump to 0.5…1.0 bar.
 Activate and flush each jetting element generously.
 Remove the jetting element only if necessary and flush directly from the heating block.
 Caution: The inlet for the air supply must stay free of adhesive!
16. Restore the readiness for operation

 Drain the system pressure: Set the pressure controller back to 0 bar and open the drain screw until the
 system pressure is relieved.
 Insert a new or cleaned filter cartridge in the glue distributor of the melter.
 Insert new or cleaned filter cartridges at the applicator heads.
 Close the drain screw (2) again.
 Increase the pressure at the pressure regulator of the pump to 0.5…1.0 bar. Activate and flush each jetting
element to remove air bubbles from the system.
 Tighten the new or cleaned nozzles at the jetting elements. Wait until the nozzles are heated up.
 Increase the pressure at the pressure regulator of the pump to the original value.
 Activate and flush each jetting element through the nozzles.
 Check the proper function of the applicator heads. The cleaning is completed herewith.
AIGER CONFIDENTIAL
D000138676
Rev. 06; 26.09.2018
7.6.6 Heavy deposits in the tank
In the event of heavy deposits, cleaning oil can be used to soften.

Caution: If oil is used, there is a risk of oil spots occurring in the area of the
adhesive application in production after the system has been cleaned.
Use the cleaning oil in the tank only. Under no circumstances may cleaning oil
be pumped through the entire system. If used in the heated hoses, undesirable
clotting may occur, even after complete cleaning.
1. Fill in cleaning oil

 Fit the filter screw plug (without filter) again.
 Close the drain screw (2).
 Fill the tank with cleaning oil up to above the ribs.
 Heat up the cleaning agent. Heat the cleaning oil to 140 °C. In case of other cleaning agent
 observe the information of the producer.
Under no circumstances may the cleaning oil be heated to above 160º C. Heat
and use the cleaning oil once only.
2. Flush the pump with cleaning oil

 Remove the filter screw plug.
 Increase the pump pressure to 0.5…1.0 bar until the oil runs out steadily without contaminations.
 Set the pump pressure back to 0 bar. Fit the filter screw plug (without filter) again.
3. Let the heated appliance stand idle for approx. 1 hour

 Remove any crusts in the tank which don't come off of their own accord by means of a wooden spatula.
4. Drain the cleaning oil from the tank

 Remove the filter screw plug.
 Increase the pump pressure to 0.5…1.0 bar and pump out the oil until the tank is completely empty.
 Set the pump pressure back to 0 bar. Fit the filter screw plug (without filter) again.
 Activate the temperature lowering (ca. 100° C)
5. Clean the tank with a rag free of fluff
AIGER CONFIDENTIAL
D000138676
Rev. 06; 26.09.2018
7.6.7 Flushing the heated hoses
Heavy deposits in the heating hoses can be removed by rinsing the hoses at
high pressure. The adhesive becomes semi-fluid by reducing the processing
temperature.
1. Cleaning agent and expendables:

 New adhesive
2. Reduce the temperature of the heated hoses

 To increase the viscosity of the adhesive, reduce the temperatures of the heated hoses.
Recommendation:
15…20º C under the normal operation temperature.
3. Relieve the system pressure

 Set the pressure controller back to 0 bar.
 Place a temperature-resistant receptacle under the drain aperture at the distributor block.
 Open the drain screw (2). The pressure is relieved when no more hotmelt emerges. Close the drain
screw (2) again.
4. Disconnect the heated hose

 Prepare a temperature-resistant receptacle.
 Disconnect the heated hose at the head and place it in the prepared receptacle.
5. Flush the heated hose
After the lower temperature is reached, increase the pump pressure continuosly
from 1.0 to 6.0 bar until the hotmelt runs steadily out of the hose aperture.
Caution: Risk of high pressure and hot adhesive splashes at the hose aperture!
 Flush generously until no more contaminations are visible.

 Set the pressure controller back to 0 bar.
6. Connect the heated hose to the head again.

7. Do this for each heated hose …
8. Set the temperature of the heated hoses to their normal value again.
AIGER CONFIDENTIAL
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Rev. 06; 26.09.2018
7.7 Maintenance preservation directions

In case the machine is to be conserved for a long time, follow the sequence below:
- Turn off and unplug all supplies to the machine;

- Unplug the supplies from workshop’s network;
- Carefully clean up the machine;
- Place the machine onto a wooden pallet;
- Grease the metal parts;
- Wrap the machine with packing lubricated paper.
AIGER CONFIDENTIAL
D000138676
Rev. 06; 26.09.2018
7.8 Troubleshooting
Nr Possible case Possible reason Action
Always ensure that the

Battery fuse not switched off
SITOP UPS – Red light battery fuse is switched off
1 during extended period of
indication – Battery fault during long periods of
storage of the machine
storage.
Insufficient oil in the lubrication

Top up the oil in the system
system
Oil pressure too low Check the suction end of the

2 The pump is sucking in air.
(RMM) pump.
Pressure sensor not adjusted. Adjust pressure sensor.
Chiller is not working Cooling agent leak during Have qualified technician
3
(RMM) storage/transportation. check and top up the coolant.
Adjust the vacuum of the

The filters do not pass next to the
fluted drum; adjust the
Dynamic rod break sensor.
4 double accelerator rollers.
(RMM)
Adjust the sensor for dynamic
Sensor not adjusted.
rod break.
Check the sensor and the

Splicing mechanism does Revolutions per minute sensor.
reflective plate.
5 not start.
Adjust coefficient from the touch Change coefficient from the
(RMM)
panel. touch panel.
Statistics does not work. Filter counting sensor not working Adjust the filter counting
6
(RMM) correctly sensor.
AIGER CONFIDENTIAL
D000138676
Rev. 06; 26.09.2018
Nr Possible case Possible reason Action
Optical measuring device Filter rod has changed its position.

- Correct the paper path by
detects paper SIKORA head detects larger non-
adjusting the paper guides.
overlapping issue: glue zone.
Check that side seam is
RMM>CHECK AND
Paper is fed incorrectly to side completely sealed and no
ADJUST FILTER ROD
7 seam gluing nozzle, causing loose paper or overlapping
OVERLAPPING .CLEAN
overlapping and loose paper end. appears.
BULLET ROLLER.
AUTOMATIC DIAMETER Bullet roller has glue deposits on it
- Clean thoroughly the bullet
CONTROL IS OFF. causing paper dragging and
roller.
(RMM) twisting.
Check the suction end of the

Insufficient/uneven Air in the system.
triacetine pump.
8 distribution of plasticizer.
(TOM) Check the speed/wear of the
Brush speed.
brush.
Have the bearings

Bearing play
Stretching rollers heat checked/replaced.
9 up/Motor overload.
(TOM) Tangled filament around the Untangle/remove any filament
axles. strands.
Change rollers speed.

Filament rolls up around Recommended (approx.):
10 the rollers. Incorrect roller speeds. V1+V2+V3 ->1.05÷1.2;
(TOM) V2 -> 1.2÷1.4;
V2+V3 -> 1.05÷1.15
Adjustment of the air nozzles.

Filament dust increase
11 Decrease air supply.
(TOM)
Filament quality.
AIGER CONFIDENTIAL
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Rev. 06; 26.09.2018
Level sensors. Adjust the sensors.

Overfilled/empty
12 capsule hopper.
(OIM) Adjust the vibro transport
Vibro transport.
coefficients.
Check the synchronization

Fist capsule between the wheels.
“Flying” capsule Check vacuum supply.
13
(OIM)
Check the position of the
Second capsule
feeding wheel cam.
Height of the feeding wheel

Broken capsule
14 Incorrect adjustments. cam.
(OIM)
Synchronization of the wheels.
Adjust the position of the

Position of the insertion wheel in
insertion wheel in the insertion
the insertion tongue.
Bad cross-section tongue.
15
(OIM)
Incorrect TOM adjustments. Adjust the filament banding.
AIGER CONFIDENTIAL
D000138677
D000138677 Electrical data
Rev. 03; 29.01.2019
Electrical data .....................................................................................................8.2

8.1 Preface .........................................................................................................8.2
8.1.1 Chapter objective............................................................................................. 8.2
8.1.2 Chapter purpose .............................................................................................. 8.2
8.2 Software description ....................................................................................8.3
8.3 Access levels ..............................................................................................8.10
8.4 Screens .......................................................................................................8.12
8.5 How to: Connect to PLC network ...............................................................8.13
AIGER CONFIDENTIAL
D000138677
Rev. 03; 29.01.2019
Electrical data
8.1 Preface
- Software description
- PLC basic information
- Access levels structure
- HMI template – assignment of functions to buttons
- Faceplate – assignment of functions to buttons
- Help visualization

Note: This chapter provides general information on the software, access levels and the basic structure and
principles of the Human-Machine interface. The illustrations herein are purely exemplary.
AIGER CONFIDENTIAL
D000138677
Rev. 03; 29.01.2019
8.2 Software description
Machine Software Terms of Use & Copyright Policy
Copyright notice. © Copyright 2013
Aiger Group AG. All rights reserved.
Any rights not expressly granted herein are reserved. All intellectual property rights, software and its
contents belong to Aiger Group AG and/or its licensors. No part of the software may be reproduced or
adapted in whole or in part without our express prior written consent.
The Customer is granted an exclusive USE ONLY license with the following provisions:
(i) No third parties other than the specific Customer are allowed to make copies in part or as a whole
of the software and programs included with Aiger Group AG’s equipment and its components.
(ii) Using, copying or uploading the software to any other equipment which is not manufactured by
Aiger Group AG is strictly prohibited.
(iii) Customer or any other third parties are restricted from performing any modifications to the
software. Such can be made by Aiger Group AG upon request for the specific request or need. All
copyright and other proprietary notices contained in the original materials must be retained on any
copies of the materials.
AIGER CONFIDENTIAL
D000138677
Rev. 03; 29.01.2019
Description of the programmable logic controller Siemens Simatic S7-300:
The MPI.DP interface is used to connect additional Simatic components, such as programming device, OP, S7
controllers and distributed I.O. Extensive networks can be built up in DP interface module. The sematic CPU has
three interfaces:
- MPI/DP;
- Profibus DP;
- Profinet;
The CPU memory can be divided into three areas (fig.1):
(Fig.1)
1. Load memory
The load memory is located on the SIMATIC Micro Memory Card. The size of the load memory corresponds
exactly to the size of the SIMATIC Micro Memory Card. It is used to store code blocks, data blocks, and system
data (configuration, connections, module parameters, etc.).
Blocks that are identified as not relevant for execution are stored exclusively in the load memory. You can also
store all the configuration data for your project on the SIMATIC Micro Memory Card.
CAUTION
Downloading user programs and hence operating the CPU is only possible if a SIMATIC MMC is
inserted.
If you pull out the SIMATIC MMC while the CPU is in RUN mode, the CPU goes to STOP mode and the
drives are shut down in accordance with your programming in the STEP 7 user program.
This is why you should only remove the SIMATIC Micro Memory Card when the CPU is in STOP.
AIGER CONFIDENTIAL
D000138677
Rev. 03; 29.01.2019
2. System memory
The system memory is integrated in the CPU and cannot be expanded.
It contains
● the address areas for bit memories, timers, and counters
● the process images of the inputs and outputs
● local data
3. Work memory
The main memory is integrated in the CPU and cannot be extended. It is used to execute the code and process
user program data. Programs only run in the main memory and system memory.
The following illustration shows the operator control and display elements of a CPU 317-2 PN DP:
① Status and error indicators

② Slot for the SIMATIC Micro Memory Card
incl. the ejector
③ Terminals of the integrated inputs and
outputs
④ Power supply connection
⑤ Interface X1 (MPI)
⑥ Mode selector
(fig.2)
On delivery, the software is already installed.
Before replacing the software, you must check the software version. Aiger
Engineering LTD does not accept liability for changes that were not made with
Aiger Engineering LTD knowledge or for any resulting malfunction of or damage
to the machine.
AIGER CONFIDENTIAL
D000138677
Rev. 03; 29.01.2019
The figure below shows the integrated digital inputs/outputs of the CPU with open front doors.
Status and error indicators

LED designation Color Meaning
SF red Hardware fault or software error
MAINT yellow Maintenance demanded (without function)
DC5V green 5 V power supply for CPU and S7-300 bus is
OK
FRCE yellow LED is lit: Active force job
LED flashes at 2 Hz: Node flash test function
RUN green CPU in RUN mode
The LED flashes during start-up at a rate of 2
Hz, and in stop mode
at 0.5 Hz
STOP yellow CPU in STOP, or HOLD or start-up
The LED flashes at a rate of 0.5 Hz when a
memory reset is
requested, and at 2 Hz during the reset.
Fig. 3
Number Designation
① Digital inputs (PIN 2 to 10)
② Digital input (PIN 11) and digital outputs (PIN 14 to pin 19)
AIGER CONFIDENTIAL
D000138677
Rev. 03; 29.01.2019
The following illustration shows the operator control and display elements of an A5S-MCE AMK controller.
(fig.3)
AIGER CONFIDENTIAL
D000138677
Rev. 03; 29.01.2019
Connection/LED Use
X01 Supply
X20/H3 Ethernet
X22 USB port
X41 Profibus DP Slave
X60/H2 Ethernet (2)
X85/H5 Real-time Ethernet slave
X86/H4
X120 Analogue inputs and square-wave input
X121 Binary inputs
X122 Binary outputs and probe inputs
X137/H8 ACC bus master
X185/H7 Real-time Ethernet master (2)
X186/H6 Real-time Ethernet master
X235 USB device
Before loading the application programs, you should perform a general reset to ensure that no old
program blocks remain on the CPU.
If a memory card is inserted during the general reset, the program will
automatically be copied from these to the CPU.
The general reset deletes all parameters and calibration settings made via the
user interface. After the update, parameters therefore have to be reloaded from
the display to the CPU.
AIGER CONFIDENTIAL
D000138677
Rev. 03; 29.01.2019
Performing a general reset with the PG or PC (STEP 7)
1. Connect the PG or PC to the CPU.

2. Start the Simatic Manager.
3. Select “PLC –> Display Accessible Nodes” and choose the appropriate object “MPI= <Node Address>
/ modules”.
4. Set the CPU to STOP with menu item “PLC / Operating Mode...” or by operating the CPU mode
selector switch.
5. General reset: select menu item “PLC / Clear-Reset” and confirm.
6. After the general reset, set the CPU to RUN with menu item “PLC/Operating Mode”.
(fig.4)
AIGER CONFIDENTIAL
D000138677
Rev. 03; 29.01.2019
8.3 Access levels

The following table illustrates the different devices and resources used in the electrical/software part of the
machine. Each device/resource has a separate user group, access level and a shortlist of recommended personnel,
that are granted access for configuration and set up.
Devices/Resources: Group user: Description: Recommended personnel

The user is used for any
PLC Admin changes or updates on  Not provided
the PLC software.
9. The user has all
permissions of the rest
of the HMI groups, as
numerated from 1 to 8.
“Admin” user can
create and delete
HMI Admin groups, also create  Not provided
users and set
passwords for groups
below. The user can
also change the
settings of the levels
AIGER
from 1 to 9.
7. This group user can
set hardware settings
of the machine, related
to engineering limits.  Not provided
HMI OEM_Admin
Also has permissions of
group 4 (Technician)
and group 7 (Current
group).
5. Administrator for the
groups below:
USER_Admin 4. Technician  Not provided
HMI
3. Statistic_Admin
2. Brand_Admin
1. Operator
5. Administrator for the

groups below:
4. Technician  Service staff
HMI CLIENT_Admin
3. Statistic_Admin  Management staff
2. Brand_Admin
1. Operator
4. Setting speed, time
durations,
Technician  Service staff
HMI temperatures. Also can
adjust technical settings
related to BRAND.
AIGER CONFIDENTIAL
D000138677
Rev. 03; 29.01.2019
3. Has permissions to  QA staff

Statistic_Admin
HMI reset the current
 Management staff
statistic.
2. Has permissions to  QA staff
HMI Brand_Admin register and delete
 Management staff
brands.
1. Monitors
temperatures, speeds,
Operator alarms – cannot  Operator staff
HMI
set/adjust technical
parameters. Change
language.
Change/update
CAMERA Admin software of the visual  Not provided
inspection camera.
Change/update
software for PILZ  Not provided
PILZ Level 1
safety system. Level 1
– full access.
Level 2 – viewing  Not provided
PILZ Level 2
access only.
IP address of VIOLA
AIGER
VIOLA IP admin router – used to setup  Not provided

the router.
ALS IP Aiger ALS IP address.  Not provided
Used to set/change
parameters of  Not provided
UPS aiger
configurable UPS
modules.
Crypted device  Not provided

Admin Crypting PLC functions.
(Siemens etc.)
All resources/devices that are operated with access regulation are

listed in the table above. Please be informed that not all of them may
be in use on one machine in particular.
AIGER CONFIDENTIAL
D000138677
Rev. 03; 29.01.2019
8.4 Screens
The HMI (Human-Machine Interface) is software functional platform that enables control and monitoring of the
machine. It is accessed from the Main Operational Panel which can be located from the illustration below:
Fig. 5
Detailed description is provided in “Appendix 2 – HMI and procedures” and is intended for the machine
operators to get acquainted with the HMI screen that is used to control and monitor the machine.
AIGER CONFIDENTIAL
D000138677
Rev. 03; 29.01.2019
8.5 How to: Connect to PLC network
1. Ping the IP address of the PLC to check whether you have connection to the network. If no connection is
established, check the cable.
2. Verify the connection – DO NOT CONNECT THROUGH WAN port (as illustrated).
Fig. 6
3. CONNECT DIRECTLY to PLC following the outlined steps below:
3.1 Switch OFF the power supply of the machine.

3.2 Loosen the screws on the service cover of the electrical cabinet (pos.1).
3.3 Open the electrical cabinet and pull the connection cable through the service port (pos.1).
3.4 Check the network cable from the PLC (pos.2) and trace it to either network switch (pos.3).
3.5 Insert the connection cable into the switch where the PLC is connected.
3.6 Close the electrical cabinet. Turn ON the power supply of the machine. Ping the IP of the PLC to
verify the connection.
1
2
Fig. 7
AIGER CONFIDENTIAL
D000138678
D000138678 Format change
Rev. 02; 31.07.2018
9 Format change ...................................................................................................9.2

9.1 Preface .........................................................................................................9.2
9.1.2 Chapter purpose .................................................................................................. 9.2
9.2 Changing the Inlet ledger and outlet ledger ................................................9.3
9.3 Changing the Paper Guides .........................................................................9.4
9.4 Changing the Counterweight .......................................................................9.4
9.5 Changing the double acceleration rollers ....................................................9.5
9.6 Changing the fluted drum ............................................................................9.6
9.7 Changing the transfer drum .........................................................................9.8
AIGER CONFIDENTIAL
D000138678
Rev. 02; 31.07.2018
9 Format change
9.1 Preface

- Changing format parts of the machine

- Service staff
AIGER CONFIDENTIAL
D000138678
Rev. 02; 31.07.2018
9.2 Changing the Inlet ledger and outlet ledger

Simply unscrew the screws that hold the inlet (pos.2) and outlet (pos.1) ledger to the ledger holder and replace
them with the format ones. (fig.1)
Screws 1 2
1 2
(fig.1)
For Correct adjustment of the Inlet and Outlet ledger please see chapter 6 from RMM
Operation manual.
AIGER CONFIDENTIAL
D000138678
Rev. 02; 31.07.2018
9.3 Changing the Paper Guides

Unscrew the screws that hold the paper guides (pos.25) and replace them with the format ones (fig.2)
Screws
(fig.2)
9.4 Changing the Counterweight

Unscrew the 2 screws that hold the counterweight (pos.1) and replace it with the format one (fig.3).
Screws
(fig.3)
AIGER CONFIDENTIAL
D000138678
Rev. 02; 31.07.2018
9.5 Changing the double acceleration rollers

Before you start dismounting anything, first unplug all cables that are connected to the double accelerator
motor, this should be done with all the mains switched off.
Dismount the plate of the double accelerator assembly by unscrewing the screws, which hold it to the base
plate.
Dismount the flat belt from the belt pulley.
Dismount the circlips of each pulley together with their spring washers. Lift the belt pulleys up and dismount
their cotters (fig.4.1).
Now when you have dismounted the belt pulleys, you can replace the double acceleration rollers (pos.1) with
the format ones (fig.4.2)
Circlips Screws
Belt pulley (fig.4.1)
1
(fig.4.2)
The mounting of the roller is performed by following the dismounting directions in reverse order.
AIGER CONFIDENTIAL
D000138678
Rev. 02; 31.07.2018
9.6 Changing the fluted drum

Step1
Dismounting the fluted drum
Remove the strip that holds the set of air hoses to the fluted drum (pos.1) by unscrewing its screws. Dismount the
strip together with the hoses. Remove the circlip that holds the fluted drum. Dismount the fluted drum together
with the flange.
Unscrew the screws that hold the flange to the fluted drum (fig.5.1).
Circlip
Screws
Set of hoses
Strip
Screws (fig.5.1)
Dismount the outer ring (pos.2) of the fluted drum by unscrewing its set screws. (fig.5.2)
Dismount the inner ring (pos.3) of the fluted drum by unscrewing its screws. (fig.5.2)
Set Screws Screws
(fig.5.2)
AIGER CONFIDENTIAL
D000138678
Rev. 02; 31.07.2018
Step 2
Mounting the fluted drum
Now when you have the fluted drum dismounted you can easily change it with the format one.
Mount back the flange to the format fluted drum. Mount the ring (pos.3) to the fluted drum. (fig.5.3)
After you have secured the ring (pos.3) to the fluted drum, mount back the fluted drum to the base frame. Once
you have mounted the fluted drum to the base frame, proceed with the mounting of the outer ring (pos.2) to the
fluted drum (fig.5.3). And finally mount back the strip with the air hoses.
Screws
Set Screws
2
3
(fig.5.3)
For fine adjustments of the fluted drum please refer to the RMM Operation Manual.
AIGER CONFIDENTIAL
D000138678
Rev. 02; 31.07.2018
9.7 Changing the transfer drum

Before you start dismounting the old transfer drum, firstly mount the two separate side rings (pos.1) on each side
of the format transfer drum (fig.6.1)
1 2
1 1
1 (fig.6.1)
After you have mounted the format rings, dismount the vacuum block from the transfer drum (pos.2) by unscrewing
the set screw situated on the bottom side of the vacuum block.
Lift the rollers of the output transport. Dismount each of the guides that guide the belt of the transfer drum and
release the belt itself from the drum (fig.6.2).
Dismount the transfer drum by unscrewing the set screw on the inner side of the drum (fig.6.2).
Set screw Output transport rollers
(fig.6.2)
2 Vacuum block Guide
AIGER CONFIDENTIAL
D000138678
Rev. 02; 31.07.2018
If necessary loosen the screw (pos.1) and lift the sensor holder (pos.2) in order to take out the transfer drum
(fig.6.3).
2 1
(fig.6.3)
To mount the format transfer drum just follow the dismounting instructions in reverse order.
AIGER CONFIDENTIAL
D000182510
D000182510 Appendix 1 - Backup and restore
Rev. 02; 12.07.2019
1 Appendix 1 - Backup and restore ........................................................................1.3

1.1 Preface ...............................................................................................................1.3
1.1.1 Chapter objective .........................................................................................1.3
1.1.2 Chapter purpose ...........................................................................................1.3
1.2 Machine Software Terms of Use & Copyright Policy .................................1.4
1.3 Quick reference tables ....................................................................................1.6
1.4 USB drive folder structure ............................................................................ 1.10
1.5 PLC backup and restore ............................................................................... 1.11
Backup and restore - Siemens S7 300 ............................................... 1.11
Backup and restore - Siemens S7-1200/S7-1500 .......................... 1.17
Backup and restore - Lenze 32XXC .................................................... 1.19
Backup and restore – PILZ .................................................................... 1.30
1.6 HMI backup and restore .............................................................................. 1.32
Backup and restore - Siemens TP177B/MP177/KTP400 ............... 1.32
Backup and restore - Siemens 700/1200/1900 Comfort ............. 1.35
Backup and restore – Lenze P300/P500 .......................................... 1.43
Backup and restore - Siemens SIMATIC IPC ...................................... 1.45
1.7 Drives backup and restore ........................................................................... 1.47
Backup and restore - Lenze 8200 ....................................................... 1.47
Backup and restore – Lenze 9400 ...................................................... 1.54
Backup and restore - AMK A5/A4...................................................... 1.56
Backup and restore - KW/KWD with KW-R06 ................................ 1.65
Backup and restore - FESTO CMMP-AS-A5 ...................................... 1.69
Backup and restore - Siemens S120-CPU310 .................................. 1.78
1.8.1 Back-Up IPC and NI Crio Controller:................................................... 1.81
1.8.2 Restore IPC Image .................................................................................. 1.85
AIGER CONFIDENTIAL
D000182510
Rev. 02; 12.07.2019
1.8.3 Restore CRio files.................................................................................... 1.87

1.8.4 Backup using Clonezilla ......................................................................... 1.89
1.8.5 Restore using Clonezilla......................................................................... 1.99
1.8.6 Deleting image using shell ..................................................................1.107
1.8.7 Create Clonezilla bootable USB .......................................................1.111
1.8.8 Backup and restore – Beckhoff IPC ...................................................1.116
AIGER CONFIDENTIAL
D000182510
Rev. 02; 12.07.2019
1 Appendix 1 - Backup and restore

1.1 Preface

- All programmable devices
- Backup and restore procedures

- Service staff
- Management staff
Please note that in this chapter are listed all programmable devices used in
Aiger. They are not all installed on the machine. On the actual machine is
used a combination of controllers for PLC, HMI and drives.
AIGER CONFIDENTIAL
D000182510
Rev. 02; 12.07.2019
1.2 Machine Software Terms of Use & Copyright Policy
Copyright notice. © Copyright 2013

Aiger Group AG. All rights reserved.
Any rights not expressly granted herein are reserved. All intellectual property rights, software and its
contents belong to Aiger Group AG and/or its licensors. No part of the software may be reproduced
or adapted in whole or in part without our express prior written consent.
The Customer is granted an exclusive USE ONLY licese with the following provisions:
(i) No third parties other than the specific Customer are allowed to make copies in part or as
a whole of the software and programs included with Aiger Group AG’s equipment and its
componenets.
(ii) Using, copying or uploading the software to any other equipment which is not
manufactured by Aiger Group AG is strictly prohibeted.
(iii) Customer or any other third parties are restricted from performing any modifications to
the software. Such can be made by Aiger Group AG upon request for the specific request
or need. All copyright and other proprietary notices contained in the original materials
must be retained on any copies of the materials.
The electrical installation of the machine is designed for indoor use and the air temperature must not
exceed 40o C and fall below 15o C. Do not run the machine in places where high humidity is likely to
occur.
Preserve the machine at temperature between 15o C and 35o C.
The electrical equipment of the machine works normally if the following conditions for the electrical
parameters are met:
• Voltage: from 0.9 to 1.1 of operating voltage.
• Frequency: from 0.99 to 1.01 of nominal frequency. Short-term frequency from 0.98 to
1.02 is allowed.
• Upper harmonics: the presence of upper harmonics by the means of the sum of the second
to the fifth harmonic must not exceed 10% of total effective value of the voltage between
active wires.
• Asymmetry: voltages of zero phase sequence and negative phase sequence must not
exceed with more than 2% the voltage of positive phase sequence.
• Voltage surges: the duration of the voltage surges must not exceed 1,5 msec., and the
peak value must not exceed 200% of the amplitude value of the power supply.
AIGER CONFIDENTIAL
D000182510
Rev. 02; 12.07.2019
• Voltage fall: not more than 20% of the amplitude value of the power supply.
Please note that the original software of the machines can be granted to the
client only after the warranty period expires.
AIGER CONFIDENTIAL
D000182510
Rev. 02; 12.07.2019
1.3 Quick reference tables
Types of components
Additional software
# Brand Model Type Download link
required for backup
1 Siemens CPU 3XX-DP
2 Siemens CPU 315T 2-DP PLC SIMATIC Manager
—
3 Siemens CPU-224
4 Siemens IM151-8 PN/DP
5 Siemens CPU300 PN DP https://support.industry.siemens.
6 Siemens S7-1500 com/cs/document/109740158
PLC TIA Portal
/simatic-step-7-(tia-portal)-
7 Siemens S7-1200 v14-trial-
download?dti=0&lc=en-WW
8 Siemens TP177B
9 Siemens MP177 SIMATIC ProSave https://support.industry.siemens.
10 Siemens KTP400 HMI com/cs/document/10347815/s
11 Siemens 700 Comfort ervicetool-simatic-
SIMATIC ProSave prosave?dti=0&lc=en-WW
12 Siemens 1200 Comfort
(Optional)
13 Siemens 1900 Comfort
14 Siemens S120-CPU310 DRIVES SIMATIC Manager —
https://support.industry.siemens.
“SIMATIC IPC com/cs/document/109756568
15 Siemens IPC IPC
Restore" application /easy-backup-and-restore-of-
simatic-ipcs?dti=0&lc=en-BG
Original PLC
https://www.lenze.com/bg-
software
16 Lenze 32XXC PLC bg/produkti/easy-engineering-
PLC designer /
tools/plc-designer/
WebConfig
17 Lenze P300
HMI WebConfig —
18 Lenze P500
19 Lenze 8200
DRIVES — —
20 Lenze 9300
21 Lenze 8400 https://www.lenze.com/en-
EASY Starter
DRIVES de/application-knowledge-
22 Lenze 9400 /»Engineer«
base/article/201200390/1/
23 AMK A4 https://amk-
24 AMK A5 DRIVES Aipex ProLite group.com/en/product/aipex_
25 AMK KW – R06 pro_engineering_tool
https://www.festo.com/net/bg_
Festo Configuration
26 FESTO CMMP-AS-A5 DRIVES bg/SupportPortal/default.aspx
Tool
?q=fct&tab=4&s=t#result
27 NI cRIO-9082 RT http://www.ni.com/download/n
PLC NIMAX i-system-configuration-
28 NI NI cRIO-9039 RT 18.0/7382/en/
https://www.pilz.com/en-
PILZ PLC PNOZmulti
29 PILZ GB/company/news/articles/08
Configurator
5115
AIGER CONFIDENTIAL
D000182510
Rev. 02; 12.07.2019
https://infosys.beckhoff.com/en
Beckhoff Service glish.php?content=../content/10
30 Beckhoff C6930 IPC
Tool 33/sw_os/4382502411.html&i
d=
Industrial PC 19" IPC https://clonezilla.org/download
31 Beckhoff Clonezilla
s.php
PLC = Programmable Logic Controller

TYPES
HMI = Human-Machine Interface

IPC = Industrial PC
DRIVES = Inverters and drive controllers
AIGER CONFIDENTIAL
D000182510
Rev. 02; 12.07.2019
List of components on each machine
SAFETY
MACHINE PLC DRIVES HMI
SYTEM
Siemens S7-1200F
MATRIX NEO — — Beckhoff IPC
NI cRIO-9039 RT
Siemens S120
Siemens CPU 315T
OI 350 FESTO CMMP-AS- — Siemens MP177
2-DP
C4-3A
AMK A4
ROD MAKER Siemens S7-1500F Siemens TP1900
AMK A5 —
MODULE Siemens CPU1214C Comfort
KW+R06(8+1)
COMBI AMK A5
Siemens CPU 315- Siemens MP177 -
TRANSFER —
2PN/DP KW+R06(3) 10 “
MODUL
COMBI AMK A5
Simatic IM151-8
SEGMENT — —
PN/DP KW+R06(5)
MODULE
Siemens CPU 1511F- Siemens S120
OBJECT 1 PN CU310 Siemens TP700
—
INSERTER MOD Siemens CPU 315T FESTO CMMP-AS- Comfort
3-DP A5
TOW OPENER Siemens CPU 1511F- AMK A5 Siemens TP700
—
MODULE 1 PN KWD-2 RW06(6) Comfort
ADDI-VES Siemens TP700
Siemens 1511-F Lenze 8400 —
LOADING MOD Comfort
Lenze HMI 7 “-
TU Lenze 3231C I700(2) PILZ
P300
Lenze HMI 7 “-
MTF Lenze 3231C Lenze 8400 PILZ
P300
Siemens CPU 1511-1
PN Siemens TP1200
P 300 HL i700 PILZ
Comfort
Lenze 3251C
Siemens IM151-8 Siemens TP700
AIGER B300 HL Lenze 8400 PILZ
PN/DP Comfort
Lenze 3200 Siemens TP700
W 300 HL Siemens 1500 PILZ
i700 Comfort
Siemens IM151-8 Lenze 8400(2) Siemens TP700
OW 300 HL PILZ
PN/DP Lenze 9400* Comfort
AIGER CONFIDENTIAL
D000182510
Rev. 02; 12.07.2019
Siemens IM151-8 Siemens TP700

STM 300 HL Lenze 8400 PILZ
PN/DP Comfort
SHAPED FILTER Siemens TP700
Siemens 1511-F — —
MODULE Comfort
AIGER CONFIDENTIAL
D000182510
Rev. 02; 12.07.2019
1.4 USB drive folder structure

Below in the illustration is presented the folder structure of the USB memory stick. Description of the
different directories is provided in the table that follows.
Fig. 1
No Folder name Description

1. Root This is the root folder of the USB drive (the main directory).
1.1. Backup In this folder are saved the backup files for PLC controllers, HMI panels
and drives (drive controllers inverters).
1.2. User data This is the folder, where user data is saved – brand settings and user
administration data.
1.3. Utilities In this folder can be found third-party software, which is used to backup
different types of software, depending on the manufacturer.
1.1.1. PLC Backup of PLC software is saved in this folder.
1.1.2. HMI Backup of HMI panel software is saved in this folder. HMI = Human-
Machine Interface
1.1.3. DRIVES Backup of drives controller/inverter parameters are saved in this folder.
1.2.1. Brand settings Backup of brand settings is saved in this folder.
1.2.2. User Backup of user administration data is saved in this folder.
administration
NOTE:
The outlined structure is valid for backup files and parameters which are intended to be saved on a USB
stick. Not all devices have this functionality. Dedicated memory cards are provided for devices that do
not support USB stick backup.
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1.5 PLC backup and restore

Backup and restore - Siemens S7 300
Requirements:
- “SIMATIC Manager” software;

- Memory card;
- Qualified personnel;
In order to create a backup, it is necessary to have the original project and PLC password.
1.5.1.1 Backup - Siemens S7 300

(Instructions apply to CPU 3XX-DP/CPU 315T 2-DP/CPU-224/IM151-8 PN/DP/CPU300 PN DP)
1. Turn on the power supply of the machine with the existing memory card inserted.
2. Open the project (software) with SIMATIC Manager.
3. Select the controller (fig.2) and activate “Copy RAM to ROM” function (fig.3)
Fig. 2
Fig. 3
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4. Go online (fig.4)
Fig. 4
5. Copy all online data blocks in the offline program. By doing this it is ensured that the relevant
data in the project are stored. (This is the project for backup.)
- After going online, mark all data blocks (DB) and copy them (click the right-hand button and
then click “Copy”):
Fig. 5
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- Go offline
Fig. 6
- Minimize the offline project and close the online project (fig.7)
Fig. 7
- Go to the offline project and click the right-hand button and select “Paste” (fig.8).
Fig. 8
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- Click “All”.
Fig. 9
6. Turn off power supply.
7. Insert the new memory card.
8. Turn on the power supply.
9. Select the controller, which memory is to be saved.
Fig. 10
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10. Activate “Save Memory Card”.
Fig. 11
11. Save the content to “Memory Card”.
- While saving the following window appears:
Fig. 12
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- After saving is completed, press the “Close” button.
Fig. 13
With that the backup process has been completed.
1.5.1.2 Restore - Siemens S7 300

(Instruction applies to CPU 3XX-DP/CPU 315T 2-DP/CPU-224/IM151-8 PN/DP/CPU300 PN DP)
Proceed in accordance with the cases listed below
1. Faulty controller (memory card is not damaged) – new memory card is not necessary. Continue
to procedure 2.
2. Turn off power supply => Replace the controller => Insert the old card => Turn on power supply
3. Faulty controller and faulty memory card, or faulty memory card only – In this case it is
necessary to use a new card with saved backup, or reprogramming of the device otherwise. For
devices that do not have an external memory card, there is no difference between this case and
case 1.
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Backup and restore - Siemens S7-1200/S7-1500
Requirements:
- TIA Portal;
- SIMATIC memory card;
1.5.2.1 Backup - Siemens S7-1200/S7-1500

With STEP 7 (TIA Portal) you have the option of generating the project data for the CPU modules of the
S7-1200/S7-1500 also as files without downloading the project to a CPU or to a SIMATIC memory card.
- You can save these generated files on an SMC (SIMATIC Memory Card) and then download
them to the CPU without STEP 7 (TIA Portal).
- In this way you can also use the SIMATIC Automation Tool to download your project data to the
CPU.
- STEP 7 (TIA Portal) does not have to be installed on your PC to download the project data to the
CPU.
- You can send the files by e-mail, then copy them to the SMC and download them to the CPU
without STEP 7 (TIA Portal) having to be installed on the recipient's computer.
- If you download your project data to the CPU directly from the STEP 7 (TIA Portal), the data is
stored automatically on the SMC slotted in the CPU. If necessary, you can copy the data from
the card using a standard SD card reader.
You have the three options below to generate the online card data.
Download configuration directly to the memory card

Slot the SMC in the card reader of your computer
and open the Project Tree in STEP 7 (TIA Portal).
After the card reader has recognized the SMC in

STEP 7 (TIA Portal), in the Project Tree under
"Card Reader/USB Memory > Add User-defined
Card Reader" you see the entry "SD Card > (G:)
SIMATIC MC (Program)".
In the Project Tree you mark the CPU station, in

our example "PLC_1 [CPU 1516-3 PN/DP]"
(fig.14).
Now drag-and-drop the station to the drive of

your SIMATIC Memory Card "(G:) SIMATIC MC
(Program)" and follow the instructions in the
"Download" dialog.
After error-free compilation the project data is Fig. 14

stored on the SMC as online card data. You can
now slot the SMC in the CPU.
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Download configuration directly to a USB memory stick
Slot the USB memory stick in the USB port of your

computer and open the Project Tree in STEP 7 (TIA
Portal).
After the USB stick has been recognized in STEP

7 (TIA Portal), in the Project Tree under "Card
Reader/USB Memory > USB DISK Pro USB
Device" you see the entry "(F:) MK_Siemens
[Program]".
In the Project Tree you mark the CPU station, in

our example "PLC_1 [CPU 1516-3 PN/DP]"
(fig.15).
Now drag-and-drop the station to the drive of
the USB stick "(F:) MK_Siemens [Program]" and
follow the instructions in the "Download" dialog.
After error-free compilation the project data the

file "S7_JOB.SYS" and the folder "SIMATIC.S7S"
are on the USB stick.
Fig. 15
Download the configuration to a file folder of the computer

You can also store the online card data directly in a
folder on your hard disk without having to go through
the procedure with a memory card or USB stick. For this
you must create the desired folder once as "User-
defined Card Reader". Proceed as follows.
In the Project Tree you open the folder "Card

Reader/USB memory".
Double-click "Add User-defined Card Reader". The

"Search folder" dialog opens.
Navigate to the drive (drive D:, for example) on which

you want to store the configurations and click the "Create
new folder" button.
Assign a name ("Reader" in this example) and click OK.
Fig. 16
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1.5.2.2 Restore – Siemens S7-1200/S7-1500

Proceed in accordance with the cases listed below
1. Faulty controller (memory card is not damaged) – new memory card is not necessary. Continue
to procedure 2.
2. Turn off power supply => Replace the controller => Insert the old card => Turn on power supply
3. Faulty controller and faulty memory card, or faulty memory card only – In this case it is
necessary to use a new card with saved backup, or reprogramming of the device otherwise. For
devices that do not have an external memory card, there is no difference between this case and
case 1.
Backup and restore - Lenze 32XXC

1.5.3.1 Backup - Lenze 32XXC
Requirements:
- Backup & Restore application/ WebConfig;
- SD card with application credits/ USB stick;
A backup, restore or update can be carried out in the following ways:
A. On the Engineering PC via ...
• »Backup & Restore« application,
• »WebConfig«,
• Windows® Explorer.
B. Directly on the Controller via »Backup & Restore« application (Windows® CE).
Creating a backup on the Engineering PC (recommended variant)

How to carry out a backup on the Engineering PC:
1. Connect a USB device to the Engineering PC.
2. Start »Backup & Restore« on the Engineering PC.
3. Change to the Backup tab.
Fig. 17
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4. Select the (pos.1, fig.17) USB stick.

5. Assign a (pos.2, fig.17) backup name in the input field (length: 2 - 16 characters).
6. Click the (pos.3, fig.17) Start button.
A control file is written to the USB device into the "/Backup" directory.
7. Remove the USB device from the Engineering PC.
8. Connect the USB device to the Controller of which you want to create a backup.
9. Restart the Controller (with connected USB device) by mains switching.
If Windows® CE systems are used, the Controller is restarted automatically.
10. After starting the Controller, remove the USB device from the Controller.
Creating a backup on the Controller

Note!
Cabinet Controllers with DVI interface (3200 C, 3231 C, 3241 C, 3251 C) require an external monitor
panel.
How to carry out a backup on the Controller:

1. Connect a USB device to the USB interface of the Controller.
2. Start »Backup & Restore« on the Controller.
3. Change to the Backup tab.
Fig. 18
4. Assign a (pos.1, fig.18) backup name in the input field (length: 2 - 16 characters).
5. Click the (pos.2, fig.18) Start button.
A control file is written to the USB device into the "/Backup" directory.
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Creating a backup using the »WebConfig«
When the Refresh button is clicked, the values from the Controller are re-imported.
When the Submit button is clicked, only the values that have changed are overwritten.
In order to log in enter:

Username: admin
Password: admin
How to carry out a backup using the »WebConfig«:

1. Connect a USB device to the USB interface of the Controller.
2. Start the »WebConfig«.
Fig. 19
3. Click the menu item (pos.1, fig.19) Backup Restore -> Backup.
4. Select the main action (pos.2, fig 19) Backup in the display area.
5. Assign a (pos.3, fig 19) backup name in the input field (length: 2 - 16 characters).
6. Select the (pos.4, fig 19) Start Backup action and confirm this selection via the (pos.5, fig 19) Submit
button.
• A control file is written to the USB device.
• The Controller is restarted.
• The backup is written to the USB device.
Creating a backup with the Windows® Explorer (on the directory/file level)
If there is no (executable) Controller or the Controller does not start correctly, a backup can be
executed via the Windows® Explorer.
Note!
Only create a backup if the Controller is executable.
For carrying out a backup with the Windows® Explorer, only use USB sticks that have
previously been used for a backup.
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How to carry out a backup using the Windows® Explorer:
1. Connect a USB device to the Engineering PC.

2. Start the Windows® Explorer.
3. Change to the directory [USB flash drive]:\Backup\Copy_Backup_file.
4. Copy the Backup.xml file to the higher-level directory [USB flash drive]:\Backup.
Note: If there is a Restore.xml file in this directory, it has to be deleted.
5. Only for the Controller 3200 C/p500:
Copy the menu.lst file from the directory [USB flash
drive]:\Backup\Copy_Backup_file to the root directory [USB flash
drive]:\.
7. Connect the USB device to the Controller of which you want to create a backup.
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Creating a backup SD card from the original software
Please note that the original software of the machines can be granted to the
client only after the warranty period expires.
Requirements:
- Original project;
- PLC designer application;
- SD card with application credits;
In order to create a backup, it is necessary to have the original project.
To prepare the SD card for backup, insert the card into a computer and create a text file, as displayed
on fig. 20, containing:
- IP Address (1);
- Subnet Mask (2);
- Default Gateway (3),
where “X” represents the network number, and “Y” the number that will be used for connection with
the machine.
Once the file is created, save it on the SD card.
Note: The file must be named “ip”.
1
2
3
Fig. 20
In order to create the backup on the SD card:

1. Connect the PLC to the computer using a Profinet cable. Make sure the computer in the same
network as the PLC and the IP address is 10.0.X.Z.
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2. Open the project with the PLC Designer application;

3. Form the list of devices, double click the Lenze 32XX controller , as displayed (fig. 21, pos. 1);
Fig.21
4. Double click “Gateway-1 (fig. 22, pos. 2) or ”Scan network, (fig. 23, pos. 3). The IP (10.0.X.Y)
address of the card shall appear on the screen.
2 3
Fig.22 Fig.23
5. Select the IP address and choose “Set active path” (fig. 23, pos. 4);
6. Select the button form the toolbar in order to go online and download the software to
the controller.
7. Select “Online” (fig. 24, pos. 5) from the menu and choose “Create boot application for
devices from Lenze” in order to save the software to the SD card.
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Fig.24
8. The software is downloaded and the backup is created.
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1.5.3.2 Restore - Lenze 32XXC

Carrying out a restore on the Engineering PC (recommended variant)
How to carry out a restore on the Engineering PC:

1. Connect a USB device with available backups/updates to the Engineering PC.
2. Start »Backup & Restore« on the Engineering PC.
3. Change to the Restore/Update tab.
Fig. 25
4. Select the USB stick (pos.1, fig 25).

5. Select the Restore action (pos.2, fig 25).
Available backups/updates are shown.
6. Select a backup/update (pos.3, fig 25).
7. Click the Start button (pos.4, fig 25).
A control file is written to the USB device.
9. Connect the USB device to the Controller on which you want to carry out a restore.
• The backup selected is loaded to the Controller.
• If Windows® CE systems are used, the Controller is restarted automatically.
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Carrying out a restore on the Controller
How to carry out a restore on the Controller:

1. Connect a USB device with available backups/updates to the Controller.
2. Start »Backup & Restore« on the Controller.
3. Change to the Restore/Update tab.
Fig. 26
4. Select the Restore action (pos.1, fig.26).

Available backups/updates are shown.
5. Select a backup/update (pos.2, fig.26).
6. Click the Start button (pos.3, fig.26).
A control file is written to the USB device.
• The backup selected is loaded to the Controller.
• If Windows® CE systems are used, the Controller is restarted automatically.
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Carrying out a restore with the »WebConfig«

When the Refresh button is clicked, the values from the Controller are re-imported.
When the Submit button is clicked, only the values that have changed are overwritten.
How to carry out a restore with the »WebConfig«:
1. Connect a USB device with available backups/updates to the Controller.

2. Start the »WebConfig«.
Fig. 27
3. Click the menu item Backup Restore -> Restore Update (pos.1, fig.27).
4. Select the main action Restore in the display area (pos.2, fig.27).
5. Select the desired display area (pos.3, fig.27) of the backup/update files from the selection list.
• Up to ten backups are shown in the display area.
• Here you can select the available backups 1 ... 10, 11 ... 20, or 21 ... 30.
Note: If more than 30 backups are available on a USB flash drive, only the first 30 backups can be
selected via the »WebConfig«.
6. Select a backup/update file (pos.4, fig.27).

7. Select the Start Restore Update action (pos.5, fig.27) and confirm this selection via the Submit
Button (pos.6, fig.27).
• A control file is written to the USB device.
• The backup selected is loaded to the Controller. (For purposes of safety, a backup is created
beforehand.)
• After the restore, the Controller is restarted.
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Carrying out a restore with available backup card
1. Turn off the power supply.

2. If the controller is faulty, proceed to replace the controller. In the new controller, insert the old
memory card (only if it is not damaged).
3. If the memory card is faulty, proceed to replace the memory card with the backup card.
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Backup and restore – PILZ
Requirements:
- “PNOZmulti Configurator” application;

- Memory card;
1.5.4.1 Backup - PILZ
1. Open the PNOZmulti Configurator.

2. Click on Project, then click Open to open the unzipped project.
Fig. 28
3. After the project is opened select Level 1 as access level and enter the correct password.
Fig. 29
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4. Go to PNOZmulti tab and click on Download to Chip Card. The process of recording the backup
on the card is started.
5. In case the interface is not set up correctly, go to PNOZmulti -> Set interfaces…
Fig. 30
6. Set Chip card reader port to USB.
1.5.4.2 Restore – PILZ

6. If the controller is faulty, proceed to replace the controller. In the new controller, insert the old
memory card (only if it is not damaged).
7. If the memory card is faulty, proceed to replace the memory card with the backup card.
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1.6 HMI backup and restore

Backup and restore - Siemens TP177B/MP177/KTP400
Requirements:
- “SIMATIC ProSave” application;

- USB stick;
1.6.1.1 Backup - Siemens TP177B/MP177/KTP400
The process for backup/restore requires the installation of “SIMATIC ProSave”. Please check “Utilities”
folder of the backup USB stick and install the application, or else visit the official website of SIEMENS to
download it.
1. Open the application SIMATIC ProSave
In the field General we set up:
- Device type – Operation Panel to which we are connecting.

- Connection – The type of communication we use to connect to the panel (in this case PROFINET)
- Connection parameters – The address for communication set in the panel.
Fig. 31
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Settings in the “Backup” tab:

- Data type – Select the type of information that requires back up.
- Save as – Choose a path to the target folder and name of the file.
- Start backup – Start creating the backup file.
Fig. 32
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1.6.1.2 Restore - Siemens TP177B/MP177/KTP400
Settings in the “Restore” tab:
- Opening – Choose a path to the folder where the backup file we want to restore is. After
choosing the file in the field “Contents” is displayed the type of Operation Panel and the type
of information that is saved on this file.
- Start restore – Click on this button to start loading the file.
Fig. 33
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Backup and restore - Siemens 700/1200/1900 Comfort

1.6.2.1 Automatic backup
Requirements:
- USB stick / memory card;

If you enable automatic backup, the Comfort Panel saves all the data necessary for operation on a
SIMATIC HMI memory card (SD card). You can slot the SIMATIC HMI memory card (SD card) into any
operator panel of the same type. When you switch on the power on the identical operator panel the
"Use system card?" message prompts you to enable the Service concept. The contents of the SIMATIC
HMI memory card (SD card) are copied automatically into the internal memory of the operator panel.
Then the operator panel is rebooted. In the Comfort Panel manual, the section given below informs you
how to parameterize automatic backup on the SIMATIC HMI memory card (SD card): "Comfort Panels >
Commissioning the device > Using the service concept > Enabling the service concept".
Notes:
- The decisive advantage of the automatic backup is that the data is continuously updated
automatically on the system memory card.
- The only medium permissible as system memory card (SMC) is the SIMATIC HMI memory card
(SD card) 2 Gbytes or more (6AV2181-8XP00-0AX0). The operator panel does not recognize
any other memory card as system memory card. The system memory card is a component of the
service concept of the operation panels. When you enable the service concept, all the data is
transferred from the internal memory of the operator panel to the system memory card. The
system memory card is not visible in the user interface of the operator panel nor can it be used
as a data memory.
1.6.2.2 Backup/Restore with a memory card/USB memory stick

When a backup is made, the operating system, applications and data are copied from the internal flash
memory of the operator panel to a memory card or a SIMATIC IPC USB flash drive (USB stick).
When you restore, the flash memory of the operator panel is deleted after a prompt. Then the data
backed up on the memory card or USB stick is copied to the internal flash memory.
Requirements:
An external SIMATIC storage medium (memory card or USB stick) with sufficient free space is slotted in
the operator panel. The external storage medium is formatted.
Notes:
- The "SIMATIC IPC USB flash drive" is a storage medium for IPCs, Comfort Panels and Basic Panels
of the 2nd generation. Use the "SIMATIC HMI USB memory stick" for Touch Panels, Operator
Panels and Multipanels.
- SIMATIC are preformatted ex works. You should not format them because this would render them
useless for specific functions. If the internal structure is overwritten, the storage medium is no
longer recognized in SIMATIC devices and therefore can no longer be used in those devices.
- Do not confuse Multi Media Cards with Micro Memory Cards. The abbreviations "MMC" or "MM"
might be used for both products. "SIMATIC HMI Multi Media Cards" are used in panels. "SIMATIC
S7 Micro Memory Cards" may only be used in SIMATIC S7 CPUs, modules of the ET200 series
with CPU functionality, SIMATIC Field PGs, SIMATIC Power PGs and USB Prommers.
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Preparation:
• Slot the memory card into the operator panel. Start the operator panel and open the "Control
Panel".
• Double-click:
- "Service and Commissioning" if you are using WinCC V12 to V13.
- "Backup/Restore" if your are using WinCC V11
Fig. 34
Backup:
- Preparation
First of all you run through the "Preparation" as described above.
- Select storage medium

WinCC V12 to V13:
Click the "Next" button. In the list box you select the memory card that you want to use for the backup
and then click "Next".
Fig. 35
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- WinCC V11:
In the list box you select the storage medium that you want to use for the backup/restore.
Click "Next" to continue.
Fig. 36
• Overview of the backup files:

This overview shows you all the backup files created on the storage medium. Click the "Backup" button to
continue the backup procedure.
Fig. 37
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• Backup settings:
Under “Choose your settings for Backup” item select the option for how you want the backup to be
made from your operator panel. In this case we have chosen "Complete backup with license".
Under the "File name" item you specify a name for the backup file. The program automatically
attaches the current date and time to the file name. Click "Create" to start the backup procedure.
Fig. 38
If the message is displayed indicating that a higher storage capacity is required, then proceed as follows.
Click "OK" to acknowledge the message and interrupt the backup procedure. Slot a storage medium with
a higher storage capacity into the operator panel. Restart the backup procedure.
• Terminate backup:
The backup is completed when the "Backup operation successfully completed." message is displayed.
Acknowledge the message with "OK". Remove the memory card from the operator panel.
Fig. 39
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1.6.2.3 Restore - Siemens 700/1200/1900 Comfort

1. Preparation - First of all, you run through the "Preparation" as described above.
2. Select memory card

- WinCC V12 to V13: Go to the „Restore“ menu and click „Next“. In the list box you select the
storage medium that you want to use for the restore and then click „Next“.
Fig. 40
- For WinCC V11: In the list box you select the storage medium that you want to use for the restore
and then click "Next".
3. Select file
In the list box you select the backup file that you wish to have transferred to the operator panel. Click
the "Restore" button to continue the restore procedure.
Fig. 41
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4. Run the restore procedure

A message is displayed asking whether the restore procedure is to be continued. Here, all the data of
the flash will be deleted on the operator panel. Acknowledge the message with "Yes" if you want to start
the restore procedure. Acknowledge the message with "No" and then the following message with "OK"
if you want to abort the restore.
Fig. 42
Once the restore procedure has been completed, the "Restore operation successfully completed"
message is displayed and the operator panel restarts.
Note:
Do not remove the storage medium from the operator panel during the restart!
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1.6.2.4 Backup/Restore with ProSave
Requirements:
- “SIMATIC ProSave”
- USB stick / SD card;
The process for backup/restore requires the installation of “SIMATIC ProSave”. Please check “Utilities”
folder of the backup USB stick and install the application, or else visit the official website of SIEMENS to
download it.
Preparation:
1. Establish a connection
Use a cable corresponding to the selected transfer to connect the panel to the PC. Switch on your Comfort
Panel. Set the Comfort Panel to "Transfer Mode".
2. General settings
Open ProSave and select the "General" tab. Under "Device type" you select the Comfort Panel used.
Under "Connection" you select the connection used to connect the panel to the PC, Ethernet, for example.
Under "Connection parameters" you enter the IP address of the panel.
Fig. 43
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Backup
1. Go to the "Backup" menu and in the "Data type" menu you select the data that you want to have
backed up. In this case "Complete backup with licenses". Under "Save as" you specify the path
in which the complete configuration is to be saved. Start the backup procedure by clicking the
"Start backup" button.
Fig. 44
Restore
1. Open the "Restore" menu. Under "Opening..." you open your backup file (*.brf file). Start the
restore procedure by clicking the "Start restore" button.
Fig. 45
When the restore procedure has been completed successfully, the message "The restore was successful"
is displayed in the output window of ProSave.
After a restore, the panel has exactly the same connection parameters as the panel from which the
backup originates. Make sure that no other panel has the same network parameters.
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Backup and restore – Lenze P300/P500

Requirements:
- “WebConfig” application;
- USB stick;
1.6.3.1 Backup – Lenze P300/P500

The directory of the executable file of the project (the .exe file) is “\SDCard\VisiWinNET\”.
Fig. 46
To create a backup on a USB stick, perform the following steps:
1. Open the project in VisiWinNET and click on the “Project” and then on “Deploy Locally”
Fig. 47
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2. The “_RuntimeFiles” directory opens on the local PC, where the runtime files are saved.
Fig. 48
3. Copy these files on a USB stick
1.6.3.2 Restore – Lenze P300/P500

Copy the files from the USB stick into the panel’s directory \SDCard\VisiWinNET\. Delete any leftover
files in this directory.
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Rev. 02; 12.07.2019
Backup and restore - Siemens SIMATIC IPC

1.6.4.1 Backup - Siemens SIMATIC IPC
Requirements:
- “SIMATIC IPC Restore" application;
- USB stick;
1. Creating a backup
You create backups with the "Siemens SIMATIC IPC Restore" application.
Note
The "Siemens SIMATIC IPC Restore" application is designed exclusively for backing up the configuration
data of the Acquisition IPC. You need to use a separate backup solution to back up the data generated
at runtime.
The following backups are supported:
- Creating a recovery medium for the "Restore" partition*

- Backing up the "System" partition**
*Only possible on USB storage devices

**Only possible on local drives
2. Creating recovery medium for Acquisition IPC
Acquisition IPC is supplied without a Recovery DVD. The "Factory Settings" image with the factory state
of the Acquisition IPC is stored on the "Restore" partition instead.
Recommendation: When the Acquisition IPC is switched on for the first time, create a backup of the
"Restore" partition on a USB storage device.
Requirement:
- A bootable, blank USB storage device with the Windows file system must be available.
- Windows has been properly shut down.
- The "Restore" partition is unchanged.
Procedure:
1. Reboot the Acquisition IPC.

2. Select the command "Siemens SIMATIC IPC Restore" from the boot menu.
The "Siemens SIMATIC IPC Restore" application starts.
3. Select the menu command "Copy Restore to USB-FlashDrive" and click "Next".
The required memory is determined and displayed.
4. Connect the USB storage device to the Acquisition IPC, which has at least the indicated
minimum amount of memory.
5. Select the USB storage device and click "Accept selection".
Result:
The following images are copied to the USB storage device:
- "Factory Settings" image
- If created: "User generated" image
AIGER CONFIDENTIAL
D000182510
Rev. 02; 12.07.2019
1.6.4.2 Restore - Siemens SIMATIC IPC
1. Restoring the Acquisition IPC Introduction
You create an image with the "Siemens SIMATIC IPC Restore" application.
Rules:
- If the Acquisition IPC is booted from a USB storage device, you can restore only the images from
the USB storage device.
You can additionally restore the entire hard disk.
- If the Acquisition IPC is booted without a USB storage device, only the image of the "Restore"
partition in the Siemens SIMATIC Restore application is available.
Restoring the entire hard disk
NOTICE:
All data on the hard disk is deleted.

The hard drive is formatted and all data will be deleted.
Before you restore the hard disk, ensure that:

- The data of the "System" and "Data" partitions are backed up.
- The licenses are backed up.
The "Restore complete system disk" command restores all partitions of the hard disk, for example, after
a hard disk replacement:
1. The hard disk is formatted and then partitioned.

2. The content of the "System" partition is restored based on one of the following images:
- "Factory settings"
- "User generated"
2. Restoring a "user generated" image Introduction
You can restore the "system" partition from the local hard disk or from a USB storage device.
Note
All data on the "System" partition is deleted.
Requirement:
1. The data of the "System" and "Data" partitions, including the licenses, are backed up.
2. When restoring from a USB storage device:
- A recovery medium has been created.
- Booting from USB is enabled in BIOS.
Procedure:
1. To restore the backup from a USB storage device, connect the USB storage device to the Acquisition
IPC.
2. Restart the Acquisition IPC.
3. Select the command "Siemens SIMATIC Restore" from the boot menu.
AIGER CONFIDENTIAL
D000182510
Rev. 02; 12.07.2019
1.7 Drives backup and restore

Backup and restore - Lenze 8200
Requirements:
- Keypad;
1.7.1.1 Backup - Lenze 8200
Copy parameter sets from the standard device to the keypad (cat. # 52707):
Step Key seq. Result Action

1. Connect the keypad to Function is active. The first
standard device 1 xx.xx Hz code in the user menu (C0517/1,
Lenze setting: C0050 = output
frequency) is displayed.
2. Inhibit controller The drive is coasting.
3. Select C0002 from the user
menu
4. 0002 Select C0002
5.
6. Select the correct copy The settings stored in the standard

function device or in the function module
are overwritten.
• Copy all available parameter sets (PAR1 ... PAR4, if required FPAR1) into the keypad:
– – Standard device with 80 Copy PAR1 ... PAR4 and FPAR1:
function module application -> Set "80"
I/O, AS interface,
INTERBUS, PROFIBUS,
LECOM−B, DeviceNet,
CANopen
– Standard device with all 20 Copy PAR1 ... PAR4:
other function modules -> Set "20"
• Only copy the module−specific parameter set FPAR1 into the function module:
– Only possible with 50 Copy FPAR1:
standard devices including -> Set "50"
function module INTERBUS,
PROFIBUS, LECOM−B,
DeviceNet, CANopen
7. Start copying STOre The selected parameter sets are
or copied to the keypad.
SaUe If STOrE or SaUe goes off, the
copy process is complete.
8. Enable controller The drive operates again.
AIGER CONFIDENTIAL
D000182510
Rev. 02; 12.07.2019
1.7.1.2 Restore – Lenze 8200

Copy parameter set from the keypad (cat. # 52707) to the standard device:
Step Key seq. Result Action

1. Connect the keypad to Function is active. The first
standard device 2 xx.xx Hz code in the user menu (C0517/1,
Lenze setting: C0050 = output
frequency) is displayed.
2. Inhibit controller The drive is coasting.
3. Select C0002 from the user
menu
4. 0002 Select C0002
5.
6. Select the correct copy The settings stored in the standard

function device or in the function module
are overwritten.
• Copy all available parameter sets (PAR1 ... PAR4, if required FPAR1) into the standard
device:
– Standard device with 70 Copy PAR1 ... PAR4 and FPAR1:
I/O, AS interface,
INTERBUS, PROFIBUS,
LECOM−B, DeviceNet,
CANopen
– Standard device with all 10 Copy PAR1 ... PAR4:
other function modules -> Set "10"
• Only copy the module−specific parameter set FPAR1 into the function module:
– Only possible with 40 Copy FPAR1:
standard devices including -> Set "40"
function module INTERBUS,
PROFIBUS, LECOM−B,
DeviceNet, CANopen
• Copy individual parameter sets (PARx and FPAR1 if available) to the standard device:
– Standard device with 71 Copy PAR1 and FPAR1:
I/O, INTERBUS, PROFIBUS, 72 Copy PAR2 and FPAR1:
LECOM−B, DeviceNet, -> Set "72"
CANopen 73 Copy PAR3 and FPAR1:
-> Set "73"
74 Copy PAR4 and FPAR1:
-> Set "74"
– Standard device with all 11 Copy PAR1: -> Set "11"
other function modules
12 Copy PAR2: -> Set "12"
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7. Start copying STOre The selected parameter sets are

or copied to the standard device or
SaUe to the function module.
If STOrE or load goes off, the
copy process is complete.
8. Enable controller The drive operates again.

Requirements:
- Keypad;
Copying parameter sets from the standard device into the keypad (cat. # 53781):
Step Key seq. Action

1. Connect the keypad to
standard device 1
2. Inhibit controller Terminal X5/28 = LOW
The drive coasts.
3. Select C0003 in the Select code C0003 "PAR SAVE" in the
"Load/Store" menu "Load/Store" menu using the arrow keys.
4. Change to the Display "0" and "READY"
parameter level
5. Copy all parameter set The settings saved in the keypad are
into the keypad. overwritten.
Set "11" "Save extern".
6. Start copying The "RDY" status display goes off. As

parameter value "BUSY" is displayed. If
"BUSY" goes off after approx. One minute,
all parameter sets were copied into the
keypad. The "RDY" status display is lit.
7. Change to the
code level
A Display of the operating level
B Display C0003 and "PAR SAVE"
8. Enable controller Terminal X5/28 = HIGH
9. Remove keypad from
standard device 1
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D000182510
Rev. 02; 12.07.2019
1.7.2.2 Restore - Lenze 9300

Copying parameter sets from keypad (cat. # 53781) into the standard device:
Step Key seq. Action
1. Connect the keypad to
standard device 2
2. Inhibit controller Terminal X5/28 = LOW
The "IMP" status display is it.
The drive coasts
3. Pull the plugs X5 and X6 All control terminals have the defined
"LOW" status.
4. Select C0002 in the Select code C0002 "PAR LOAD" in the
"Load/Store" menu "Load/Store" menu using the arrow keys.
5. Change to the The active parameter set is shown, e. g.
parameter level display "0" and "Load Default"
6. Select the correct copy The settings saved in the standard device
function are overwritten.
• Copy all parameter sets available into the • The parameter set that was active
EEPROM of the standard device and save before copying is overwritten.
them permanently. • The parameters are not yet active after
copying. Select parameter set and load
it in the main memory.
Set "20" "ext −> EEPROM"
• Copy individual parameter sets into the main
memory of the standard device.
Copy parameter set 1 into the main
memory:
Set -> "11" "Load ext PS1"
memory:
memory:
memory:
7. Start copying The "RDY" status display goes off. As
parameter value "BUSY" is displayed. If
"BUSY" goes off, the parameter sets
selected were copied into the standard
device. The "RDY" status display is lit.
8. Change to the
code level
A Display of the operating level
B Display C0002 and "PAR LOAD"
9. • If the function "Copy Select code C0003 "PAR SAVE" in the
all parameter sets into "Load/Store" menu using the arrow keys
the EEPROM" (C0002 and store the contents of the main memory
= 20) is selected, they permanently.
AIGER CONFIDENTIAL
D000182510
Rev. 02; 12.07.2019
might have to be
loaded in the main
memory manually.
• If the function "Copy
individual parameter
sets into the main
memory" (C0002 =
1x) is selected, they
might have to be
saved permanently in
the EEPROM
manually.
10. Plug in plugs X5 and X6
11. Enable controller Terminal X5/28 = HIGH
The drive is running with the new settings.
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D000182510
Rev. 02; 12.07.2019
Requirements:
- EASY Starter /»Engineer«;
- Memory card;
Saving parameters to the integrated memory module
Inverter parameter changes via the EASY Starter /»Engineer«, the keypad (cat. # 154731), or a master
control via fieldbus communication will be lost after mains switching of the controller unless the settings
have been explicitly saved to the integrated memory module.
General information
• In the delivery state, the Lenze setting of the parameters has been saved to the integrated memory
module. These parameters are
• the parameters of the inverter
• the parameters of the communication module plugged into the MCI interface
• the parameters of the possibly existing safety module (device variant)
• When the device or the external 24 V voltage supply is switched on, all parameters are automatically
loaded from the memory module into the main memory of the inverter.
• Full functionality of the memory module is even provided if the power supply has been switched off and
only the electronic components of the inverter are externally supplied by a 24 V DC voltage, e.g. via the
X4/24E terminal.
• The memory module can be preconfigured with customized data.
• The memory module is available as a spare part - without any data.
During operation
• Parameter sets can be saved and loaded manually.

• Using the keypad, you can press function key to save the parameter settings.
• The »EASY Starter«/»Engineer« serves to execute the saving via the icon in the toolbar or via the
device command "Save all parameter sets" (C00002/11 = "1:On / start").
• The storage process may take a couple of seconds. After the device command has been called in
C00002/11, dynamic status information ("Work in progress 20%" -> "Work in progress 40%" -> "Work
in progress 60%", etc.) is returned.
Note!
In order to prevent data inconsistencies during the saving process:

• Do not switch off the supply voltage!
• Do not remove the memory module from the device!
Automatic saving of changed parameter settings is explicitly not supported because this significantly
reduces the service life of the memory module.
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D000182510
Rev. 02; 12.07.2019
1.7.3.2 Restore - Lenze 8400
Load all parameter sets:
The C00002/6 = "1: On / start" device command reloads all parameter settings from the memory
module to the inverter.
• Can only be executed if the controller is inhibited; otherwise, the feedback C00002/6 = "6: No access
- controller inhibit" will be returned.
• All parameter changes made since the last saving of the parameter set will get lost!
• This device command has an effect on the settings of the parameters of the operating system, application
and module.
How to load the parameter settings from the memory module:
1. If the inverter is enabled, it must be inhibited, e.g. by executing the "Enable/Inhibit inverter" device
command "(C00002/16 = "0:Off / ready").
2. Execute the "Load all parameter sets" device command:
C00002/6 = "1:On / start"
The loading process may take a couple of seconds. After the device command has been called,
C00002/6 returns dynamic status information ("Work in progress 20 %" -> "Work in progress 40 %" -
> "Work in progress 60 %", etc.).
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D000182510
Rev. 02; 12.07.2019
Backup and restore – Lenze 9400

Requirements:
- EASY Starter /»Engineer«;
- Memory card;
1.7.4.1 Backup – Lenze 9400

Save start parameters
Controller parameter changes made via »Engineer« or keypad will get lost after mains switching of the
controller or loading of another application unless the settings have been explicitly saved. With the
device command C00002 = "11: Save start parameters" the current parameter settings of the active
application can be saved with mains failure protection in the memory module of the controller:
"Save start parameters" function
Tip!
With the keypad this device command can be executed via the left function key if it is currently assigned
with the function.
* In this example, application 1 is the active application
Note!
The saving process can take several seconds. Before you switch off the supply voltage after having
executed this device command, therefore be absolutely sure to check via the status display in C00003
whether the device command has been executed successfully!
1.7.4.2 Restore – Lenze 9400

Load start parameters
Via C00002 = "1: Load start parameters" the start parameters of the active application can be reloaded
from the memory module to the controller:
AIGER CONFIDENTIAL
D000182510
Rev. 02; 12.07.2019
"Load start parameters" function
• Only possible when the application has stopped and the controller is inhibited.
• All parameter changes made since the last saving of the parameter set will get lost!
• This device command only affects the settings of the operating system, application and module
parameters, the active application or the configuration selected with the function block editor remains
unchanged.
AIGER CONFIDENTIAL
D000182510
Rev. 02; 12.07.2019
Backup and restore - AMK A5/A4

Requirements:
- “Aipex ProLite” application;
- USB stick;
1.7.5.1 Backup - AMK A5/A4

The process for backup/restore requires the installation of “Aipex ProLite”. Please check
“Utilities”folder of the backup USB stick and install the application.
1. Go into online mode (1)

1
Fig. 49
2. Export data from inverter
After going online:
2.1 Select the inverter which data is to be exported (creating backup) – in this case GarnitDr_U22.5.
2.2 Select the second tab “Parameters” (pos.2, fig.50) and on the right-hand side will be loaded all
parameters for this inverter.
2.3 Right click on “Parameters selection” (pos.3, fig.50) and from the drop-down menu click on
“Export data set” (pos.4, fig.50). After that save the .xml file in a directory with the default
drive name. Do not change the name of the file!
Repeat the procedure for all inverters.
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Fig. 50
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3. Export data from AMK controller
3.1 PLC program export

After going online:
- Select the controller (ADFC in this case) (pos.1, fig.51)

- Click the “Direct mode” button (pos.1, fig.51).
- Select the controller in the tree structure on the right-hand side. You can verify that the correct
controller is selected in the yellow field below, where its name appears.
- Select “PLC” (pos.4, fig.51) and then click on “Export program” (pos.5, fig.51).
After that save the .bin file in a directory with the default drive name.
Fig.51
4. Export parameters from AMK controller

After going online:
4.1 Select the controller (ADFC in this case) (pos.1, fig.52)
4.2 Click the second tab “Parameters” (pos.2, fig.52) and on right-hand side are loaded all
controller parameters.
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4.3 Right click on “Parameters selection” (pos.3, fig.52) and from the drop-down menu select “Export
data set” (pos.4, fig.52). After that save the .xml file in a directory with the default drive name.
NOTE:
DO NOT change the default names of the exported files, otherwise they might not be imported
correctly afterwards:
Fig. 52
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4.4 Save in a table the fixed addresses of every inverter, which has been exported:
Fig. 53
4.5 Save the IP addresses of the controller:
Fig. 54
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D000182510
Rev. 02; 12.07.2019
1.7.5.2 Restore - AMK A5/A4

The process for backup/restore requires the installation of “Aipex ProLite”. Please check
“Utilities”folder of the backup USB stick and install the application
Importing data to an inverter:
1. Go into online mode
Fig. 55
2. Inverter data import:
After going online:
- Select the inverter (pos.1, fig.55), which you want to import the data to (In this case
GarnitDr_U22.5)
- Go to the second tab (Parameters) (pos.2, fig.55) and on the right-hand side will be loaded all
parameters of the inverter.
- Right-click on Parameters selection and click on Import data set from the drop-down menu.
After this select the file that you want to import.
- Repeat the procedure for all inverters.
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Importing data to AMK controller
1. Import of PLC program
Fig. 56
After going online:

Select the controller (ADFC in this case)
Click on the Direct Mode button (pos.2, fig.56).
Select the controller in the tree structure on the right (pos.3, fig.56). Ensure the controller is
selected – its name should appear in the yellow bottom field.
Select PLC (pos.4, fig.56) and then click on Import program (to the device) (pos.5, fig.56).
AIGER CONFIDENTIAL
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2. Parameters import to an AMK controller.
Fig. 57
After going online:
- Select the controller (ADFC in this case) (pos.1, fig.57).

- Go to the second tab (Parameters) (pos.2, fig.57) and on the right will be loaded all controller
parameters.
- Right-click on Parameters selection and click on Import data set from the drop-down menu.
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2.1 Enter the addresses (pos.4, fig.58). You can find them from the previously saved table with
fixed addresses for the inverters.
Fig. 58
2.2 Also enter the IP addresses of the controller. You can find them in the same table.
Fig. 59
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D000182510
Rev. 02; 12.07.2019
Backup and restore - KW/KWD with KW-R06

Requirements:
- “Aipex ProLite” application;
- USB stick;
1.7.6.1 Backup - KW/KWD with KW-R06
USB cable used for communication

between AIPEX LITE and KW-R06 USB Connection to AIPEX LITE
PARAMETERS
FLASH MODULE
Fig. 60
1. If only KW/KWD inverter is damaged /power side/ in this case It is not necessary to exchange
KW-R06 control board. In this case you must change only the inverter part KW/KWD/power side/
and keep the same KW-R06 control board /put it into the new KW/KWD/!
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- Remove complete KW/KWD servo drive, with KW-R06 boards inside;

- Remove KW-R06 control board from damaged inverter /KW/KWD/ and put it inside new one
KW/KWD;
- Mount the complete inverter set inside the cabinet and turn ON the machine;
- KW-R06 will generate an error - because the inverter part is changed. In this case please use AIPEX
LITE to reset the error (Menu “Diagnostics”, button “Error reset”).
- The machine is ready to run!
2. If KW-R06 /inverter control board/ have some problems, then you need to exchange it with a new
one.
BUT in this case you can TRY to keep the parameter set. All servo drive parameters are stored in a
small flash module on the control board- please see the picture above! In this way:
- Remove parameters flash module from the damaged KW-R06 and put it on the new KW-R06;
- Put the new KW-R06 into the inverter module and turn machine ON;
- If some errors appear, please use AIPEX LITE to reset them! (Menu “Diagnostics”, button “Error reset”).
- The machine is ready to run!
3. IF YOU EXCHANGE THE COMPLETE INVERTER SET /KW,KWD + KW-R06/.
- Open AIPEX LITE. You can download this program from our web site –
www.amk-antriebe.de
FREE DOWNLOAD after REGISTRATION! Work on Windows XP and Windows 7!
- Turn ON you servo drive and wait until the front LED’s are on;
- Connect KW-R06 to the computer by using USB cable – IMPORTANT, connection must be made only
after LED’s are ON!
- Start AIPEX LITE
- Choose the connection type to USB;
- If the connection is OK, your device will appear in the right window;
Fig. 61
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- Click on device and choose SystemInfo/radio button bellow/;
Fig. 62
- Press button “Save parameter set” and enter the name of new file for device parameters. The
parameters are stored into a file with extension *.apu.
Fig. 63
- After successful saving of the device parameter backup is DONE;
1.7.6.2 Restore - KW/KWD with KW-R06

For downloading device parameters to new device– please choose menu “Parameters”;
Right click on parameter table and choose “Data compare”;
Fig. 64
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- AIPEX LITE will ask you to choose file. In this case please choose parameter file which correspond to
exchanged device (with extension *.apu);
- Now the parameter table is divided into two colons on the left side are online parameters (actual)
and on the right side are offline parameters (from the file);
Fig. 65
- DOWNLOAD of the backup parameters is made with the arrow button on the top of the window;
- For complete parameters download please make the step above for each instance;
Fig. 66
- FOR UPLOAD/DOWNLOD of PLC parameters and/or programs use the same way as above, but use
Ethernet at starting AIPEX LITE! PLC programs are stored inside the parameter set!
- In addition, check “PLC” radio button, if you want to UPLOAD/DOWNLOAD only PLC program. Use
button “Export program (from device)” to upload PLC program or “Import program (to device)” to
download it!
In addition AIPEX LITE can be used also for diagnostic, error reset or setting up temporary parameters
of servo drives or PLC!
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D000182510
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Backup and restore - FESTO CMMP-AS-A5

Requirements:
- FESTO configuration tool;
- Memory card;
1.7.7.1 Backup - FESTO CMMP-AS-A5

Backup parameters using memory card:
1. Connect the communication cable to the RS232 port of the controller.
Fig. 67
2. Insert the Memory Card into the slot (the memory card should be ma10. 2GB and formatted
under FAT file system).
Fig. 68
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3. Check from the device manager of the Windows, on which COM port the controller is connected.
Fig 69
4. Open the FESTO configuration tool.
5. Go to the menu “Component” > “FCT Interface”.
Fig. 70
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6. Set the COM port number from the previous step and the bit rate to 9600.
Fig. 71
7. Go Online (Green icon indicate the connection is successful).
Fig. 72
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8. In the bottom of the program window there is “Memory card” tab, which you have to select.
Fig. 73
9. If the “state” indication is green the Memory card is accepted and ready for use.
Fig. 74
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10. Mark the “Read From SD After Startup” (pos.1, fig.75) option and press “Store” (pos.2, fig.75)
button to save the option on the controller memory (By choosing the option, the controller will
automatically read from the Memory Card, every time it is present into the slot and the check sum of
the Controller and Memory Card parameters are different. The Memory Card can contain more than
one backup file, but only the last one can be automatically read at startup)
Fig. 75
11. Now press ”Controller to SD” to copy all the parameter data from the controller to the Memory
Card.
Fig. 76
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1.7.7.2 Restore - FESTO CMMP-AS-A5

1. Connect the PC by using the RS232 port of the controller
Fig. 77
2. Insert the backup memory card in the slot of the controller.
Fig. 78
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3. From Windows Device Manager check the COM port where the controller is connected.
Fig. 79
4. Open Festo configuration tools. From the Component menu select FCT Interface and set up bit
rate to 9600.
Fig. 80
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5. Go online
Fig. 81
6. After going online, on the bottom of the window select Memory Card.
Fig. 82
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7. If State is lit up in green, that means that the card is accepted and ready for use.
Fig. 83
8. Click on SD>>Controller to copy all parameters from the controller’s card.
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Backup and restore - Siemens S120-CPU310

Requirements:
- “SIMATIC Manager”;
- Memory card;
1.7.8.1 Backup - Siemens S120-CPU310

2. Remove the card from the inverter.
3. Insert an empty card in the inverter.
5. Open the project (fig.84).
Fig. 84
6. Go online (pos.1, fig.81)
Fig. 85
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7. Download the project to the device. When going online, you most likely will be prompted to
download. If not prompted, click on the highlighted button in fig. 86. If not active try clicking on
the button in fig. 87.
Fig. 86
Fig. 87
8. Then click on “Copy RAM to ROM” (Fig.88).
Fig. 88
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9. Go offline by clicking the button “Disconnect from target button” (Fig.89)
Fig. 89
10. Turn off the machine and then back on.
11. Check whether the machine works with and without materials. Just to make sure that the program
of the inverter works correctly (speeds etc.)
13. Remove the card.
14. Insert the old card (the original one).
1.7.8.2 Restore - Siemens S120-CPU310
Proceed in accordance with the cases listed below:

1. Faulty motor – Reprogramming devices is not required when replacing the same motor with a
new one.
2. Faulty inverter (memory card is not damaged) – new memory card is not required (if the inverter
has a memory card). Follow the procedure below:
Turn off power supply => Replace controller => Insert old memory card => Turn on power supply.
3. Faulty controller + faulty memory card, or only faulty memory card. In this case it is necessary
to use a new memory card with saved backup, or reprogramming of the devise otherwise. For
devices that do not have an external memory card, there is no difference between variant 2 and
3.
AIGER CONFIDENTIAL
D000182510
Rev. 02; 12.07.2019
1.8.1 Back-Up IPC and NI Crio Controller:

Requirements:
- “NIMAX” application;
- Clonezilla;
- USB stick;
In order to log in enter:

Username: admin
Password: 123
1. Turn the IPC ON.

2. Using the NIMAX (National Instruments Measurement & Automation Explorer), look up the IP
address of the Ni Crio Controller.
Fig. 90
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3. Using Windows explorer go to the Controller ftp directory using the IP address from the previous
step (for example ftp:\\10.0.32.122).
Fig. 91
4. Copy the whole content of the directory to the IPC hard drive “D:\backup_crio”.
5. Insert the USB flash drive to the USB Hub inside the Matrix unit (the provided from Aiger USB
flash drive has Clonezilla software preinstalled, if yours doesn’t have this software please see
the “How to create a Clonezilla USB”).
Fig. 92
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6. Connect a keyboard (use the frond side USB socket).
Fig. 93
7. Restart the IPC (from the Windows start menu).
8. While the IPC is starting press “F7” to enter the boot menu.
9. Boot the USB flash drive to start the Clonezilla
Fig. 94
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10. Create an image of the whole hard drive of the IPC as “neo_backup_date” into the root directory
of the USB flash drive (the USB flash drive has second partition which can be used only for storing
the image file. The partition is invisible for Windows OS for security reasons. If there is already
image in the directory, you have to delete the old one in order to free space for the new file
using the “shell” of the Clonezilla. See “Deleting image using shell”). / For more information how
to create backup see “Backup using Clonezilla”. /
Time needed for creation of the image file is about 1 hour.
11. After finishing the backup process chose “reboot” to start the Windows from the hard drive.
Fig. 95
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D000182510
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1.8.2 Restore IPC Image

Requirements:
- “Clonezilla” application;
- USB stick;
1. Insert the USB flash drive to USB HUB inside the Matrix unit (the provided from Aiger USB flash
drive has Clonezilla software preinstalled, if yours doesn’t have this software please see the
“How to create a Clonezilla USB”).
Fig. 96
2. Connect a keyboard (use the frond side USB socket)
Fig. 97
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3. Turn the IPC ON (from the UPS) or restart it if it is already ON (from the Windows start menu).
4. While the IPC is starting press “F7” to enter the boot menu.
5. Boot the USB flash drive to start the Clonezilla.
Fig. 98
6. Restore the image of the whole hard drive of the IPC (“neo_backup_date” in the root directory
of the USB flash drive (the USB flash drive has second partition which can be used only for storing
the image file. The partition is invisible for Windows OS for security reasons). / For more
information how to restore backup see “Restore using Clonezilla”. /
Time needed for restoration of the image file is about 30 minutes.
7. After finishing the restore process chose “reboot” to start the Windows from the hard drive.
Fig. 99
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D000182510
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1.8.3 Restore CRio files

Requirements:
- “NIMAX” application;
- USB stick;
1. Turn the IPC ON.
2. Using the NIMAX (National Instruments Measurement & Automation Explorer), look up the IP
address of the Ni Crio Controller.
Fig. 100
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D000182510
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3. Using Windows explorer go to the Controller ftp directory using the IP address from the previous
step (for example ftp:\\10.0.32.122).
Fig. 101
4. Delete the whole content of the Controller directory.
5. Copy the whole content from the IPC hard drive “D:\backup_crio” to the controller directory (for
example ftp:\\10.0.32.122).
6. After finish the copying, restart the Crio so the new configuration can be loaded.
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D000182510
Rev. 02; 12.07.2019
1.8.4 Backup using Clonezilla

Requirements:
- USB stick;
1. Boot the USB on which you have the Clonezilla Preinstalled (JetFlashTrancend 64GB 1100 for
example).
2. Chose “Clonezilla live”.
Fig. 102
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3. Chose your language.
Fig. 103
4. Chose keyboard layout.
The default keyboard layout is US keyboard, therefore if you are using US keyboard, just
press enter (i.e. use the option "Don't touch keymap").
Fig. 104
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5. Choose "Start Clonezilla"
Fig. 105
6. Choose "device-image" option.
Fig. 106
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7. Choose "local_dev" to be able to use the USB.
Fig. 107
8. Press “Enter” to confirm.
Fig. 108
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9. Select sdb2 as image repository.
10. Choose the top directory.
Fig. 109
11. Then Clonezilla shows you the disk usage report.
Fig. 110
Press “Enter” to go next
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12. Chose “Beginner” mode.
Fig. 111
If you choose "Expert" mode, you will have some chances to choose advanced parameters, e.g.
imaging program, compression program, etc…
13. Select "savedisk" option.
Fig. 112
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14. Input image name (for example IPC img_date).
Fig. 113
15. Select the source disk "sda" we want to save.
Fig. 114
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16. Select skip checking.
Fig. 115
17. Select “Check the saved image”.
Fig. 116
By default this will be done. It's recommended to do such a check.
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18. Select “not to encrypt the iamge”.
Fig. 117
By default the image won't be encrypted. If you want to encrypt the image, it will prompt you
to enter a passphrase for the image. //NOTE// You have to remember the passphrase
otherwise the image will _NOT_ be useable in the future. There is no back door to decrypt the
image.
19. Press “Y” and then “Enter” to start the creation process.
Fig. 118
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20. Press Enter again to confirm.
21. When the process is finished chose “power off” or “reboot” to exit the application.
Fig. 119
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1.8.5 Restore using Clonezilla
Requirements:
- USB stick;
1. Boot the USB on which you have the Clonezilla Preinstalled (JetFlashTrancend 64GB 1100 for
example).
2. Chose “Clonezilla live”.
Fig. 120
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3. Choose your language.
Fig. 121
Fig. 122
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5. Choose "Start Clonezilla".
Fig. 123
6. Choose "device-image" option.
Fig. 124
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7. Choose "local_dev" be able to use the USB device.
Fig. 125
Fig. 126
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9. Select sdb2 as image repository.
10. Choose the top directory.
Fig. 127
11. Then Clonezilla shows you the disk usage report.
Fig. 128
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Press “Enter” to go next.
12. Chose “Beginner” mode.
Fig. 129
13. Select "restoredisk" option.
Fig. 130
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14. Select image name (for example IPC img_date).
Fig. 131
15. Select the target disk "sda" we want to restore.
Fig. 132
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16. Press “Y” and then “Enter” to start the restoration process.
Fig. 133
18. When the process is finished chose “power off” or “reboot” to exit the application.
Fig. 134
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D000182510
Rev. 02; 12.07.2019
1.8.6 Deleting image using shell
Requirements:
- USB stick;
To delete the image file:

1. Boot the USB on which you have the Clonezilla Preinstalled
2. Chose “Clonezilla live”
Fig. 135
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3. Chose your language
Fig. 136
Fig. 137
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5. Choose "Enter_shell"
Fig. 138
6. Choose “cmd” to open the shell.
7. Type “sudo fdisk –l” to find out what name your block device file have.
You will have output similar to this.
************************************************************************
Disk /dev/sdb: 29.4 GB, 31591497728 bytes
Units: sectors of 1* 512 = 512 bytes
Disk identifier: 0x000b2b03
Device Boot Start End Sectors Size Id Type
/dev/sdb1 * 2048 4198399 4196352 2G b FAT32 W95

/dev/sdb2 4198400 61702143 57503744 27.4G c FAT32 W95
***********************************************************
8. Type “sudo mkdir /mnt/sdb2” to create a mounting point directory.

9. Type “sudo mount –o rw /dev/sdb2 mnt/sdb2” to mount the USB flash drive.
10. Type “cd /mnt/sdb2” to navigate to the root directory of the image storage.
11. Type “sudo ls –lh” to list all files and folders in the root directory of the USB flash drive. There
should be a folder with the name of your image (for example IPC img_date)
12. Type “sudo rm –rf IPC img_date” to delete the file.
13. Type “sudo ls –lh” again, to check if the image is deleted. The root directory should be empty.
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14. Type “exit” to exit the shell and go back to the menu.
15. When the process is finished chose “power off” or “reboot” to exit the application
Fig. 139
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1.8.7 Create Clonezilla bootable USB

Requirements:
- USB stick (64GB or larger);
Here are the steps you need to perform in order to crate the Clonezilla bootable USB:
1. Download the “Clonezilla” free software from the official web site
www.clonezilla.org/downloads.php.
2. Download the “Linux live USB Creator” free software from the official web site
www.linuxliveusb.com/en/download.
3. Download the “Paragon Partition manager “free software from the official web site
www.paragon-software.com/home/pm-personal/eshop.html.
4. Insert the USB flash drive to your computer.
5. Install the “Paragon Partition manager” and start the application.
a) Delete the partition of the USB flash drive.
Fig. 140
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b) Create 2GB primary partition and format it as FAT32 volume
Fig. 141
Fig. 142
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c) Create second primary partition with the remaining space and format it as FAT32 volume
Fig. 143
Fig. 144
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d) Apply the changes.
Fig. 145
e) Close the application.
6. Install the “Linux Live USB Creator” and start the application.
a) Choose the 2GB partition of the USB drive as a target location
Fig. 146
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b) Choose the Clonezilla.iso file as a source location
Fig. 147
c) Start the installation by clicking the lightning icon
Fig. 148
d) Close the application.
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D000182510
Rev. 02; 12.07.2019
1.8.8 Backup and restore – Beckhoff IPC

1.8.8.1 Start the Beckhoff Service Tool (BST)
Requirements:
- BST USB flash drive is connected to an Industrial PC. The BST USB flash drive must be connected
directly to the Industrial PC without a USB hub or a USB extension.
- The USB flash drive is the first boot medium in the BIOS.
- Correct BST version for the Industrial PC in use.
The Industrial PC must be booted from the BST USB flash drive in order to start the BST. Observe the
boot order in the BIOS.
If the BST doesn't start, this means that the boot order has been changed or you are not using the
correct BST version for the Industrial PC in use. Check the boot order in the BIOS and whether you are
using the correct BST version.
Start the BST as follows:

1. Connect the BST USB flash drive to the Industrial PC and start the Industrial PC.
2. The BST is started and the start page is displayed.
- if the BST doesn't start -
3. Restart the Industrial PC and press [Del].
The BIOS is started.
4. Check under Boot > FIXED BOOT ORDER Priorities whether the option Beckhoff Stick is set
under Boot Option #1.
5. Check under Boot > Boot mode select whether the correct boot mode is selected for your
BST. In DUAL mode the correct boot mode is selected automatically, depending on the BST.
6. Save the settings and exit from the BIOS.
The BST is started with the correct boot order and the correct BST for Legacy or UEFI BIOS.
AIGER CONFIDENTIAL
D000182510
Rev. 02; 12.07.2019
1.8.8.2 Backup – Beckhoff IPC

You can create an image of complete storage media or individual partitions in *.tib format. You can
save the image on the BST stick, locally on the Industrial PC or on a network drive.
Requirements:
- Sufficient space on the BST stick or network drive.
Create an image as follows:
1. Click the Backup button, then click Next.
2. Select the drives and partitions you want to back up as an image.
Fig. 149
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3. In the tree view, select the destination directory where you want to save the image. Use the
Map Network Drive button to integrate a network drive.
Fig. 150
4. In the next step you can set a password and the compression level.
Fig. 151
5. Check the settings and click Proceed.
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Fig. 152
The image is created. Click Close to return to the start page.
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1.8.8.3 Restore – Beckhoff IPC
Loss of data
In this step the data on the storage media is deleted.
Back up your data before restoring an image.
You can restore an image from a storage medium or a single partition. You can use this function in the
event of an error or to create PC systems with identical configurations and settings.
Requirements:
- A previously created image on the BST stick or a network drive.
You can restore an image as follows:
1. Click the Restore button, then click Next.
2. In the tree view, select the image you want to restore. Use the Map Network Drive button to
integrate a network drive.
Fig. 153
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3. In the next step, the hard disks and partitions available in the selected image are displayed.
You can select individual partitions or complete storage media to restore.
Fig. 154
4. Select the storage medium on the Industrial PC on which the image is to be restored.
Fig. 155
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5. Check the settings and click Proceed.
Fig. 156
Once the image has been restored, click Close to return to the start page. Click the Shutdown button,
remove the BST stick and restart the Industrial PC.
AIGER CONFIDENTIAL
D000250104
D000250104 Appendix 2 – HMI and procedures
Rev. 01; 05.10.2018
Preface and Guidelines 1/1
1. Preface Guidelines for viewing document on the HMI display of the

machine:
1.1 Chapter description
The current document provides information on the functionality of the Human-Machine
By pressing the button (pos.1 – position may vary), a help window appear,
Interface (HMI) that is an integral part of the operation of the machine.
where you can find a document containing information on HMI functionality and
procedures, where necessary.
All screens are listed and described. Established procedures are also added to aid the
operator/technician.
The document opens and displays the first page (current one) always. To reach the
The chapter can be provided a PDF file, or can be viewed directly on the HMI display of help page for the screen you are currently on, press the info button (pos.2) –
the machine.
and it’ll take you directly to the needed information.
1.2 Chapter purpose

This chapter is addressed to the following personnel: 3
- Service staff
- Operator staff
- Technician staff
- QA staff
The illustrations bellow display the factory settings of the

2
machine. The parameter values can be considered default
values and can be used in case return to factory condition of
the machine is required.
1
The document can be navigated with touch gestures or with the rest of the buttons on
the left side of screen (pos.3).
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D000250104
Rev. 01; 05.10.2018
Content 1/1
Main screen and Slide-in ............................................................................ 1.3 4.3 Technical setup – Start program......................................................... 1.32
1.0/1.1 Machine information – General/Emergency line ............................ 1.4 4.4 Technical setup – Stop program ......................................................... 1.33
2. Logbook – General ................................................................................. 1.5 4.5/4.6 Technical setup – Drives diagnostic .............................................. 1.34
3. Operator setup – General ...................................................................... 1.6 4.7 Technical setup – Status variable ....................................................... 1.35
3.1 Operator setup – Display settings......................................................... 1.7 4.7.1/4.7.3 Status variable screens........................................................... 1.36
3.2 Operator setup – Bobbin change .......................................................... 1.8 4.8 Technical setup – AMK PID setup ....................................................... 1.37
3.3/3.4 Process data temperature – inner/seam ........................................ 1.9 4.9 Technical setup – Display settings ...................................................... 1.38
3.5 Operator setup – Gluing ....................................................................... 1.10 6.0 Brand Setup – General ....................................................................... 1.39
4. Technical setup – General ...................................................................... 1.11 6.1 Brand Setup – Admin ......................................................................... 1.40
4.1 Technical setup – Technical setup ........................................................ 1.13 7.0 Production – Shift log ......................................................................... 1.42
4.1.1 Technical setup– Drive settings ......................................................... 1.14 7.1/7.2 Production – Production archive 1/2............................................ 1.43
4.1.2/4.1.3 Technical setup –Service data temperature – seam/inner ........ 1.16 7.3 Production – Shifts library .................................................................. 1.44
4.1.4/4.1.5 Technical setup – Hot melt seam/inner .................................... 1.17 7.4 Production – Current shifts ................................................................ 1.45
4.1.6/4.1.7 Technical setup – PVA seam/inner gluing ................................. 1.19 7.5 Production – Time efficiency .............................................................. 1.46
4.1.8 Technical setup – Diameter control ................................................... 1.21 7.6 Production – Production history......................................................... 1.47
4.1.9 Technical setup – Cleaning cycles ...................................................... 1.24 7.7 Production – Production counter ....................................................... 1.48
4.1.10 Technical setup – Knife control........................................................ 1.25 8.0 User administration ........................................................................... 1.49
4.2 Technical setup – General .................................................................... 1.31
AIGER CONFIDENTIAL
D000250104
Rev. 01; 05.10.2018
Main screen and Slide-in 1/1

Main screen: Slide-in:
1 16 17 18 22 23 25 26 27 31 33
2 3 4 5 6 7
19 20 21 24 28 29 30 32 34 35
No Description
16 Start seam PVA (manual mode).
17 Stop seam PVA (manual mode).
18 Activate/Deactivate automatic mode for seam PVA.
8 9 10 11 12 13 14 15 19 Start inner PVA (manual mode).
20 Stop inner PVA (manual mode).
21 Activate/Deactivate automatic mode for inner PVA.
No Description 22 Start inner hotmelt (manual mode).
1 Displays currently logged in user. Button is used for log out. 23 Stop inner hotmelt (manual mode).
2 Go to Operator screen 24 Activate/Deactivate automatic mode for Inner Hotmelt.
3 Go to Technician screen. 25 Test light column.
4 Go to System parameters (OEM) screen. 26 Auxiliary drives START/STOP.
5 Go to Brand settings screen. 27 Heaters START/STOP.
6 Go to Statistics screen. 28 Activate manual bobbin change-over.
7 Go to User administration. 29 Materials ON/OFF mode.
8 Go to main screen. 30 Activate/deactivate Automatic mode.
9 Print current screen in PDF file on external USB drive. Manual knife advance. When the button pressed the pneumatic knife advancing
10 Go to alarm logbook. 31
unit is actuated, resulting in 1 (one) knife advance.
11 Display a list with currently active error messages. Reset knife advance counter. On screen 4.1.10 Technical setup – RMM – Knife
12 Go to HMI help document. 32
control – “Cut/Knife advance”.
13 Return to previous screen (Not active in Main screen). 33 Activate/deactivate Automatic mode for Diameter control.
14 Go to next screen (Not active in Main screen). 34 Increase rod diameter.
15 Go to Machine information screen. 35 Decrease rod diameter
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D000250104
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1.0/1.1 Machine information – General/Emergency line 1/1
Machine information menu is accessed by pressing button (pos.1).
It has two sub-screens – General and Emergency line.

2
1. General
Field (pos.2) of the screen contains the following information:
Machine type – Displays information about the machine type.

Machine serial number – Displays serial number of the machine.
Client – Displays the name of the client company.
Inv. soft. ver. – Displays the version of the inverter software.
PLC soft. ver. – Displays the version of the PLC software.
El. diagram ver. – Displays the version of the electrical diagram.
1
3
2. Emergency line
The “Emergency line” screen is accessed when you press “Next” button on screen
“General” – (pos.3).
It contains Aiger contact information in cases of issues, need of support or spare parts
ordering.
End of description.
4
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2. Logbook – General 1/1
No Description
Logbook of alarm messages. In this field are listed all alarms with
1
additional information such as No., time, date, etc.
1 Tooltip button. Displays information on how to solve a particular alarm
2
issue.
3 Press button to view a list of currently active alarm messages.
The field displays currently active alarm messages with additional
4
information such as No., time, date, etc.
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D000250104
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3. Operator setup – General 1/1

2 4
No Description
1 Displays maximum speed of the machine in filters per minute [fpm].
2 Displays maximum speed of the machine in meters per minute [m/min].
1 9 3 Displays actual speed of the machine [fpm].
3 10 4 Displays actual speed of the machine [m/min].
5 11 5 Set production speed [fpm].
6 12 6 Set jog speed (inch mode speed) [fpm].
7 Set startup speed [fpm].
7
8 Set bobbin change speed [% of production speed].
8 13 9 Displays glue consumption (PVA seam) [cm3/min].
14 10 Displays glue consumption (PVA inner) [cm3/min].
11 Displays glue consumption (Hotmelt seam) [cm3/min].
12 Displays glue consumption (Hotmelt inner) [cm3/min].
13 Displays actual diameter of the filter rod.
14 Displays the actual status of the measuring device.
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3.1 Operator setup – Display settings 1/1
No Description
Choose a language for the HMI. Active languages are fully colored. (blank page)
1
Inactive languages are grayed out.
Clean screen button. When the button is pressed, the touchscreen
2
becomes inactive for 30 seconds and can be cleaned.
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3.2 Operator setup – Bobbin change 1/1

Bobbin change overview:
1
2
7
3 8
4
9
5
10
6
11
5. Bobbin holder diameter = D1
6. Bobbin holder diam. correction = D2
D3 = D1 + D2
No Description 11. Calculated bobbin splice ratio – This output box displays the actual calculated
1 Displays actual machine speed in meters per minute [mpm]. bobbin splice ratio.
2 Displays actual machine speed in filters per minute [fpm]. The ratio is calculated by determining the speed [rpm] of the bobbin in use (Vbobbin)
3 Displays set bobbin change speed in % from actual machine speed. and the speed of knife head [rpm] (Vknife head).
4 Displays set bobbin acceleration speed [mpm].
5 Displays set bobbin holder diameter [mm]. When the paper is unwound from the bobbin, it decreases its diameter and therefore
6 Displays set bobbin holder diameter correction [mm]. its speed [rpm] is increased, compared to the speed of the knife head:
7 Displays actual calculated paper diameter [mm].
V𝑏𝑜𝑏𝑏𝑖𝑛
8 Set bobbin splice ratio. 𝐶𝑎𝑙𝑐𝑢𝑙𝑎𝑡𝑒𝑑 𝑏𝑜𝑏𝑏𝑖𝑛 𝑠𝑝𝑙𝑖𝑐𝑒 𝑟𝑎𝑡𝑖𝑜~ V
9 Displays actual calculated bobbin splice ratio. 𝑘𝑛𝑖𝑓𝑒 ℎ𝑒𝑎𝑑
10 Indicator showing when sensor is triggered (green); idle – (red).

11 Indicator showing when sensor is triggered (green); idle – (red). The bobbin splice occurs as follows:
When the calculated bobbin splice ratio (pos.11) matches the set bobbin splice ratio
(pos.10), then the splicing occurs.
The operator/technician usually determines a recommended set bobbin splice ratio

during the initial tests on the machine.
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D000250104
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3.3/3.4 Process data temperature – inner/seam 1/1
No Description
1 Set glue tank temperature [°C].
1 5 2 Set glue hose temperature [°C].
2 6 3 Set glue nozzles temperature [°C].
4 Set paper heater temperature [°C].
3 7 5 Displays actual temperature of glue tank [°C].
4 8 6 Displays actual temperature of glue hose [°C].
7 Displays actual temperature of glue nozzle [°C].
9 8 Displays actual temperature of paper heater [°C].
11
10 9 Displays actual temperature of cooling zone (Garniture top) [°C].
12 10 Displays actual temperature of cooling zone (Garniture bed) [°C].
Bypass visualization. Green – bypass is off, cooling is active. Red –
11
bypass is on, cooling is inactive. (Garniture top)
Bypass visualization. Green – bypass is off, cooling is active. Red –
12
bypass is on, cooling is inactive. (Garniture bed)
AIGER CONFIDENTIAL
D000250104
Rev. 01; 05.10.2018
3.5 Operator setup – Gluing 1/1
No Description
1 Set glue flow rate [g/500m] (hot melt seam).
1 (c) 2 Set start up glue flow rate [g/500m] (hot melt seam).
7
2 (b) 3 Displays actual rotating speed of the pump [rpm].
3 4 Set glue flow rate [g/500m] (hot melt inner).
8 5 Set start up glue flow rate [g/500m] (hot melt inner).
4 6 Displays actual rotating speed of the pump [rpm].
7 Set glue flow rate [cm3/500m) (PVA seam).
5
8 Set glue flow rate [cm3/500m) (PVA inner).
6
General information on “Gluing” screen
PVA glue: 1𝑔 ≈ 1𝑐𝑚3
Glue quantity = 𝐺𝑙𝑢𝑒 𝑞𝑢𝑎𝑛𝑡𝑖𝑡𝑦 = 𝑎 ∗ 𝑥 + 𝑏

b = Start up flow rate
c = Glue flow rate
x = Machine actual speed [m/min] (Vmax)
𝑐−𝑏
𝑎=
𝑉𝑚𝑎𝑥
AIGER CONFIDENTIAL
D000250104
Rev. 01; 05.10.2018
4. Technical setup – General 1/2

2 4 Bobbin change overview:
1 11
3 12
5
6
7
8
9
10
- 5. Bobbin holder diameter = D1
6. Bobbin holder diam. correction = D2
D3 = D1 + D2
No Description
1 Displays maximum speed of the machine in filters per minute [fpm]. 11. Calculated bobbin splice ratio – This output box displays the actual calculated bobbin
2 Displays maximum speed of the machine in meters per minute [m/min]. splice ratio.
3 Displays actual speed of the machine [fpm]. The ratio is calculated by determining the speed [rpm] of the bobbin in use (Vbobbin) and the
speed of knife head [rpm] (Vknife head).
4 Displays actual speed of the machine [m/min].
5 Set production speed [fpm]. When the paper is unwound from the bobbin, it decreases its diameter and therefore its speed
6 Set jog speed [fpm]. [rpm] is increased, compared to the speed of the knife head:
7 Set startup speed [fpm].
8 Set bobbin change speed [% from production speed]. 𝐶𝑎𝑙𝑐𝑢𝑙𝑎𝑡𝑒𝑑 𝑏𝑜𝑏𝑏𝑖𝑛 𝑠𝑝𝑙𝑖𝑐𝑒 𝑟𝑎𝑡𝑖𝑜~
V𝑏𝑜𝑏𝑏𝑖𝑛
V𝑘𝑛𝑖𝑓𝑒 ℎ𝑒𝑎𝑑
9 Set bobbin holder diameter [mm].
10 Set bobbin holder diameter correction [mm]. The bobbin splice occurs as follows:
11 Set filter rod length [mm].
12 Set fine filter rod length. When the calculated bobbin splice ratio (pos.11) matches the set bobbin splice ratio (pos.10),
then the splicing occurs.
The operator/technician usually determines a recommended set bobbin splice ratio during the
initial tests on the machine.
Continue to next page for information on “Format setup”.
AIGER CONFIDENTIAL
D000250104
Rev. 01; 05.10.2018
4. Technical setup – General 2/2

2 4
1 11
3
12
5
6
7
8
9
10
-
Information on “Format setup”: (blank page)
11. Filter rod length – Set filter length (e.g. 120 mm)
12. Fine filter length – Use as correction value for filter rod length increase/decrease.
Procedure:
1. Enter filter rod length in input field pos.11, e.g. 120 mm.
2. Measure the length of some sample rods.
3. If their length differs from the set filter rod length, use the “Fine filter length”
coefficient to correct the length to the specified one.
This setting is very precise, so usually the adjustment is achieved by changing the 3rd or
4th number after the decimal - .
The filter rod length is set by a service technician during the initial tests
of the machine. Very rarely does the value of “Fine filter length” differ
from “1.0000”.
AIGER CONFIDENTIAL
D000250104
Rev. 01; 05.10.2018
4.1 Technical setup – Technical setup 1/1

3
To run the machine in manual mode, press the button on the faceplate (highlighted in
green). When the button is pressed, the machine is running in Automatic mode. When
1 2 the button is released, the machine is running in Manual mode.
No Description
Displays the actual speed of the drives [rpm]. Activation/deactivation of
1
drives in manual mode.
2 Displays the actual filter diameter produced by the machine [mm].
Choose machine section to run in manual mode. In automatic mode all
3
sections are selected.
AIGER CONFIDENTIAL
D000250104
Rev. 01; 05.10.2018
4.1.1 Technical setup– Drive settings 1/2

8 9 Bobbin accelerator diagram:
1
2 4
3 10
4 2
11
5
12
13 3
6
14
7
15
SPLICE
2. Paper advance time – This is the time for initial advancing of paper. Initial
advancing of paper refers to feeding out paper that must be rolled on the splicing
mechanism (pos.A) to ensure readiness for splicing.
No Description
1 Set calibration factor for bobbin accelerator.
2 Set paper advance time [s]. A
3 Set paper advance speed [m/min].
4 Set advance speed up time [s].
5 Displays actual speed of bobbin accelerator [m/min].
6 Displays speed of main drive during last splice cycle [m/min].
7 Displays speed of bobbin accelerator drive during last splice cycle [m/min].
3. Paper advance speed – This is the speed of the initial paper advance.
8 Set blower startup speed [%].
9 Displays the actual speed of the blower [rpm].
4. Advance speed up time – This is the time it takes for the replacement bobbin to
10 Set production speed of the blower [%]. reach the speed of the machine.
11 Calculate accelerator over speed correction.
12 Set Double accelerator over speed [% of production speed]. Last splice cycle:
13 Displays the actual speed of the Double accelerator [m/min]. Here are shown the speeds [in m/min] of the Main drive and Bobbin accelerator during
14 Set calibration factor of the paper tension. the last splicing cycle. If the speed of the Bobbin accelerator does not match the speed
15 Displays actual speed of the paper [m/min]. of the Main drive, use the Calibration factor (pos.1) to correct the speed of the Bobbin
accelerator.
This setting is usually done by a service technician during the initial tests of the machine
and is dependable on the properties of the paper. It may require to be readjusted if
a new type of paper is used.
AIGER CONFIDENTIAL
D000250104
Rev. 01; 05.10.2018
4.1.1 Technical setup – Drive settings 2/2

8 9 Information on Paper Tension:
The Paper Tension unit (illustrated below) ensures that the paper feed speed matches
1 the production speed of the machine. The paper tension drive speed (paper pulling
2 roller illustrated – pos.A) is increased/decreased, depending on readings from the
3 10 enconder on the swinging arm (pos.B).
4
11 If paper tension is high – the speed of the paper tension roller is decreased and if the
5
12 paper tension is low – the speed of the paper tension roller is increased.
6 13 The goal is the speed pos.15 to match the production speed of the machine.
14
7 The value in input field pos.14 is used to calibrate the speed of the paper tension
15
drive.
Information on Double Accelerator:
The Double Accelerator is always driven with a higher speed than the rest of the
machine, because it needs to accelerate the filter rods sufficiently for them to enter the
grooves of the Fluted Drum.
A
The value of “Acc. over speed” (pos.12) is set in percentages from the machine speed,
in order to ensure correct entry of the filter rods in each groove of the Fluted drum.
AIGER CONFIDENTIAL
D000250104
Rev. 01; 05.10.2018
4.1.2/4.1.3 Technical setup –Service data temperature – seam/inner 1/1

1 2 3 4 No Description
1 Set minimum temperature of heating zone [°C].
2 Enter set point temperature of heating zone [°C].
3 Displays actual temperature of heating zone [°C].
4 Set maximum temperature of heating zone [°C].
5 Displays actual temperature of cooling zone [°C].
6 Set temperature for warning message [°C].
7 Set temperature for error message (machine stop) [°C].
8 Set delay time for deactivation of cooling when machine is stopped [s].
9 Green – cooling ON. Red – cooling OFF.
Operation overview:
1. Set minimum temperature of heating zone – error when not reached. Machine cannot start if
the set minimum temperature of the heating zone is not reached. Serves also as lower limit of set
point temperature (pos.2), no value lower than the minimum temperature can be entered as set
5 6 7 8 9 point temperature.
2. Set point temperature – this is the target temperature. When a value is entered in set point
(pos.2), the zone/device starts heating up to this value.
4. Set maximum temperature of heating zone – when the actual temperature (pos.3) reaches the
maximum (pos.4), this is indicative of a problem, therefore the machine displays an error
message and stops.
Maximum temperature also serves as upper limit of set point temperature (pos.2), no value
greater than maximum temperature can be entered as set point temperature.
Garniture cooling: It doesn’t have a set point temperature, only levels for warning and error
messages.
When an error level is reached (pos.7) the machine stops. Let the garniture cool down to normal
levels and start the machine again. If issue persists, investigate the cause for temperature rise.
8. Delay – A delay timer; after the set time has passed (after the machine has stopped), the
cooling is deactivated.
9. When the indicator is green – the cooling is active. When the indicator is red – the bypass is
activated and the cooling is deactivated.
AIGER CONFIDENTIAL
D000250104
Rev. 01; 05.10.2018
4.1.4/4.1.5 Technical setup – Hot melt seam/inner 1/2

2 4
No Description
1 Set glue flow rate [cm3/500m].
2 Displays glue flow rate [g/500m].
1 3 Set start up flow rate [cm3/500m].
(c) 10
3 4 Displays start up flow rate [g/500m].
(b) 11
5 5 Set test glue flow rate [cm3/min].
12 6 Displays test glue flow rate [g/500m].
7
7 Displays actual pump rotating speed [rpm].
6 8 Displays calibration quantity [cm3]; [g].
8 13 14 15 9 Input measured quantity [cm3]; [g].
9
1 10 Set calibration factor - K.
11 Set calibration time [s].
12 Input Hot melt density [g/cm3].
Select to calibrate glue quantity regardless of nozzle position. The nozzle
13
will eject glue in either front or back position.
14 Start calibration.
15 Recalculate calibration factor.
𝐺𝑙𝑢𝑒 𝑞𝑢𝑎𝑛𝑡𝑖𝑡𝑦 = 𝑎 ∗ 𝑥 + 𝑏
b = Start up flow rate
c = Glue flow rate
x = Machine actual speed [m/min] (Vmax)
𝑐−𝑏
𝑎=
𝑉𝑚𝑎𝑥
𝑐−𝑏
𝐺𝑙𝑢𝑒 𝑞𝑢𝑎𝑛𝑡𝑖𝑡𝑦 [𝑔] = ∗ 𝑥[𝑚⁄𝑚𝑖𝑛] + 𝑏
𝑉max[𝑚⁄𝑚𝑖𝑛]
After calibration:
𝐴𝑓𝑡𝑒𝑟 𝑐𝑎𝑙𝑖𝑏𝑟𝑎𝑡𝑖𝑜𝑛 𝑄𝑇𝑌 [𝑔] = 𝐾 ∗ 𝐺𝑙𝑢𝑒 𝑞𝑢𝑎𝑛𝑡𝑖𝑡𝑦 [𝑔]
K – Calibration factor
Go to next page for calibration procedure.
AIGER CONFIDENTIAL
D000250104
Rev. 01; 05.10.2018
4.1.4/4.1.5 Technical setup – Hot melt seam/inner 2/2

2 Hotmelt glue calibration procedure:
1
(c) 10 STOP button
3
(b) 11
5
12
7
6 1. Stop the machine from the main operator panel – .
8 13 14 15 2. Enter value of 1.000 for calibration factor (pos.8).
9 3. Set calibration time (e.g. 60 sec.).
1
4. Prepare a suitable container to collect the output glue from the nozzle. Press start
calibration button – (pos.12).
The calibration procedure is started, the nozzle feeds out glue with “Test glue flow rate”
(pos.2)
5. Measure the collected glue quantity and enter it in “Measured glue quantity”
(pos.11).
6. Press recalculate button (pos.13). The recalculated calibration factor appears

in pos.8.
End of procedure.
AIGER CONFIDENTIAL
D000250104
Rev. 01; 05.10.2018
4.1.6/4.1.7 Technical setup – PVA seam/inner gluing 1/2

No Description
1 Set glue flow rate [cm3/500m] – .
1 2 Set test glue flow rate [cm3/min].
8 3 Set on speed [m/min].
2 9
3 4 Set off speed [m/min].
10 Set overfeed multiplier value. The overfeed multiplier is used to provide
4 11 5
5 extra quantity of glue during startup – .
6 Set overfeed on speed [m/min].
6
7 12 13 7 Set overfeed off speed [m/min].
8 Set calibration factor. See procedure for calibration on the next page.
9 Set time for calibration [s].
10 Displays actual calibration quantity.
11 Enter measured glue quantity.
12 Start calibration button.
13 Recalculate calibration factor. The recalculated value appears in pos.8
Pos.7
Pos.6
VGLUE PUMP
Pos.4
Pos.3
VRMM t
= Glue flow rate (pos.1) * Calibration factor (pos.8)
= Glue flow rate (pos.1) * Overfeed multiplier (pos.5) * Calibration factor (pos.8)
Go to next page for calibration procedure.

AIGER CONFIDENTIAL
D000250104
Rev. 01; 05.10.2018
4.1.6/4.1.7 Technical setup – PVA seam/inner gluing 2/2
PVA glue calibration procedure:
1 8
2 9
3 10
4 11
1. Stop glue flow from slide-in screen for Seam PVA or Inner PVA – .
5 2. Enter value of 1.000 for calibration factor (pos.8).
6 3. Set calibration time (e.g. 60 sec.).
7 12 13
4. Prepare a suitable container to collect the output glue from the nozzle. Press start
calibration button – (pos.12).
The calibration procedure is started, the nozzle feeds out glue with “Test glue flow rate”
(pos.2)
5. Measure the collected glue quantity and enter it in “Measured glue quantity”
(pos.11).
6. Press recalculate button (pos.13). The recalculated calibration factor appears

in pos.8.
End of procedure.
PVA glue: 1g ≈ 1cm3
AIGER CONFIDENTIAL
D000250104
Rev. 01; 05.10.2018
4.1.8 Technical setup – Diameter control 1/3

No Description
1 Set plus value of filter rod diameter or perimeter for rejection [mm].
2 Set the target diameter or perimeter of produced rod [mm].
3 Set minus value of filter rod diameter or perimeter for rejection [mm].
1 7 4 Displays actual diameter without correction [mm].
2 8 5 Set diameter correction offset [mm].
3 9 6 Displays actual diameter with correction [mm].
The machine stops with an error after the set time has passed – “Error 186: DIAMETER
4 10 7 CONTROL DEVICE”. The measuring device does not detect filter rod or the measuring
5 instruments are obscured by dirt, dust particles or else.
11
6 8 Displays the actual status of the measuring device.
14 Set how many filters to be rejected if an incorrect diameter is detected. After that number
12 9
if diameter value returns to targeted value the reject stops.
SP - target
diameter
Set the measured length between the centerline of the measuring device (pos.1) and the
13 10
right-hand end of the fluted drum (pos.2). Distance “L” shown in the illustration below.
11 Set control cycle time
Set for how long [ms] the automatic diameter control drive will be actuated in case of
12
deviations from target diameter.
Set deviation control limit values:
b1 a1 a2 b2  If the Sikora measurement falls between a1 and a2 there are no deviations from
the target diameter of produced rod;
13  If the Sikora measurement falls between b1 and a1 (a2 and b2) – the automatic
diameter control (12) is actuated for the set amount of time accordingly;
 If the Sikora measurement is beyond b1 or b2 - the automatic diameter control
(12) is actuated for the set amount of time accordingly.
14 Displays the overlap limit [mm]
L
2
Go to next page for correction offset adjustment

procedure of overlap limit.
AIGER CONFIDENTIAL
D000250104
Rev. 01; 05.10.2018

Adjustment procedure for calibration coefficient – Correction Offset
For correct Sikora laser measurement and correct filter rod diameter control, the following adjustments are
1 7 required:
2 8 I. Adjustment of the Correction Offset (pos. 5) as follows:
3 9
4 10
5 1. Turn off the automatic diameter control (Slide in Screen pos. 15) and start RMM with materials
11 at speed 2000 f/m.
6 14 2. After the stabilization of the diameter measurement take 10 filters from the newly produced
12 SP - target
diameter
ones. Measure their dimensions with external measuring device and calculate the average value
of the diameter (D1+D2+…….+D10)/10 = DmeasureAverage
13 3. From screen 4.1.8 take the value for filter diameter without correction (pos. 4) - DActualNoCorr
4. Calculate the difference between the externally measured DmeasureAverage and DActualNoCorr:
(DmeasureAverage- DActualNoCorr)= Result.
Input the Result in pos. 5 – Correction Offset.

b1 a1 a2 b2 5. Value displayed in pos. 6 – With Correction is the sum between Correction Offset value (pos. 5)
and Without Correction value (pos. 4).
15
II. Set the limits and values of the regulation coefficients (when regulation option selected – pos. 12
and pos. 13) as follows:
1. Start the RMM with materials at speed 2000 fpm.

2. Set the limits in which the regulation step will be changed (pos.13).
3. Set the steps with which the regulation will be made (pos.12).
Example: If the Diameter set point (pos. 2) = 5.95 then -> Reject plus (pos. 1) = 6.1; Reject minus (pos.
3) = 5.8.
4. Turn on the automatic diameter control (Slide in Screen) (pos.15) to further adjust the regulation
coefficients (pos.12 and pos.13) so the regulation of the filter diameter goes smoothly.
AIGER CONFIDENTIAL
D000250104
Rev. 01; 05.10.2018
Conclusions:
1. When the Brand parameters (see Brand section) related to the measurement and
the diameter control are correctly input, the machine operation with Overlap Limit
regulates the diameter in accordance to the set regulation coefficients.
2. In case the operation of the machine goes out of Overlap limit range, Warning
N130 appears:
RMM>CHECK AND ADJUST FILTER ROD OVERLAPPING .CLEAN BOOLET ROLLER.
6 14 AUTOMATIC DIAMETER CONTROL IS OFF.
SP - target
diameter The yellow lamp of the light column is lit ON and sound signal with frequency
2.5 HZ follows. This is indication that the paper is out of the set permitted range
of Overlap and the automatic regulation is not working.
3. The operator must adjust the paper and clean the glue from bullet roller (Also
described in chapter 7.Maintenance under Troubleshooting table).
4. When the paper is adjusted back in permitted range of Overlap, the warning
Set overlap limit
message, the light and sound signals automatically disappear and the automatic
regulation is turned ON.
Overlap adjustment procedure (pos. 14):
1. Set overlap limit (pos. 14) = 0.3mm;
2. Start the machine, with automatic regulation turned OFF;
3. Manually move the paper slowly in direction towards the operator, start with step of
0.1mm (0.2mm, 0.3mm, 0.4mm, 0.5mm );
4. For each step take 10 filters from the newly produced ones and measure their
dimensions with an external device then calculate the average value of the diameter
(D1+D2+…….+D10)/10 = DmeasureAverage;
5. Compare the results (DmeasureAverage) with the measured and calibrated value With
correction (pos. 6);
6. Find the overlap limit where DmeasureAverage and With Correction (pos. 6) are
approximately equal;
7. If in the whole range (0.1÷0.5) the DmeasureAverage and With Correction are
approximately equal, the Overlap limit (pos. 14) doesn’t require change.
8. If in the whole range (0.1÷0.5) DmeasureAverage and With Correction aren’t
approximately equal, change the Overlap limit (pos. 14) by decreasing it with 0.05
(0.25, 0.20, 0.15). Repeat the measurements from point 3 onward until
correspondence is achieved in the whole range.
AIGER CONFIDENTIAL
D000250104
Rev. 01; 05.10.2018
4.1.9 Technical setup – Cleaning cycles 1/1

Cleaning cycles diagram:
Counter reset
(pos.3, pos.6)
1 4
Number of filters
2 5 Cleaning cycle
3 6 (pos.1, pos.4)
Number of filters
Valve active Valve not

(pos.2, pos.5) active
Number of filters
No Description End of description.

1 Number of filters for cleaning cycle of the fluted drum [filters].
2 Set number of filters for the valve to remain active [filters].
Counts actual number of filters [filters]. Number is reset when value in
3
input field pos.1 is reached.
4 Number of filters for cleaning cycle of the transfer drum [filters].
5 Set number of filters for the valve to remain active [filters].
Counts actual number of filters [filters]. Number is reset when value in
6
input field pos.4 is reached.
AIGER CONFIDENTIAL
D000250104
Rev. 01; 05.10.2018
4.1.10 Technical setup – Knife control 1/4

General information on the functionality of the “Knife control” screen.
6 Knife control:
1 7 Controlling the knife advance parameters. Number of cuts per 1 knife advance,
2 number of advances before warning and machine stop.
3 8
9
4 Knife synchronization:
10
5 11 Knife synchronization parameters are used to set up the cutting position of the knife
12 and the offset of the fluted drum in relation to the knife.
Douber system:
The Douber system function is to apply dotted pattern of glue on the inner seam,
depending on the filter segment combination (when recess is formed in filter rod).
1. Knife advance – illustration, overview and recommended settings

No Description
1 Displays actual knife cuts. 1.1 Illustration
2 Displays actual knife advances.
3 Set number of knife cuts for 1 knife advance. Input limits: 20 – 20 000.
Set number of knife advances for warning message visualization. Input B A
4
limits: 20 – 20 000.
Set number of knife advances before a machine stops due to an error.
5
Input limits: 0 – 20 000.
6 Knife synchronization – current angle [°].
7 Save current angle as cutting position.
8 Shows currently saved cutting position [°].
9 Save fluted drum offset.
10 Set offset between the cutting head and the fluted drum [°].
11 Set calibration factor for the Douber system.
12 Displays actual speed of the Douber system. When the knife “A” wears out due to cutting and re-grinding, its length “B” is gradually
reduced, the advancing mechanism compensates the wear by pushing forward (blue
arrow) the knife, to compensate the length decrease of the blade.
AIGER CONFIDENTIAL
D000250104
Rev. 01; 05.10.2018

Events:
6 Knife advance – Knife is advanced when the number in field “Knife counter” (pos.1)
1 7 reaches and passes the set number value in “Cuts/Knife advance” (pos.3).
2 I.e. (1) > (3) = knife advance.
3 8
9 Warning (no stop) – Warning is displayed when the number in field “Cut/Knife
4
10 advance” (pos.2) reaches and passes the set number value in “Knife advance warning”
5 11 (pos.4).
12 I.e. (2) > (4) = Warning.
Error message No 184: RMM>KNIFE ADVANCE WARNING
Error message (machine stop) – Error is displayed when the number in field “Cut/Knife
advance” (pos.2) reaches and passes the set number value in “Knife advance stop”
(pos.5).
I.e. (2) > (5) = Error message (machine stop)
1.2 Overview of parameters, events and recommended settings Error message No 168: RMM>KNIFE ADVANCE STOP REPLACE KNIVES
1. “Knife counter” – displays the actual number of knife cuts (one cut per one When this message is displayed, the machine stops. The operator must replace the
revolution of the knife). knives. To start the machine again – press the “Reset” button to clear the error and
2. “Cut/Knife advance” – displays the actual number of knife advances. start the machine again.
3. “Cuts/Knife advance” – set the number of cuts for 1 knife advance. 1. Knife synchronization
4. “Knife advance warning” – Set the number of knife advances before a warning
message is displayed. Knife synchronization is achieved by first saving the cutting position of the knife, then
setting the offset of the fluted drum in relation to the position of the knife. The
5. “Knife advance stop” – Set the number of knife advances before an error is adjustment itself is a part of a more complex procedure, that synchronizes the actions
displayed (machine stops). of other components of the machine, such as the double acceleration rollers and vacuum
regulation of the fluted drum.
Continue to next page to go through the knife synchronization procedures.
AIGER CONFIDENTIAL
D000250104
Rev. 01; 05.10.2018

- Once you have access to the assembly, turn by hand the cutting head (B) until it
reaches cutting position. (Rotation of the cutting head is visualized on the screen in
6 output field “Current angle” (pos.6)
1 7 Cutting position is considered when one of the knifes reaches the edge of the inlet
2 ledger tube (D), as illustrated below:
3 8
9
4
10
5 11
12
1.1 Procedure for adjusting the cutting position of the knife
- Open the cover (A) of the cutting head assembly (illustrated below):
B Extreme caution is advised when carrying out this procedure.

A Wearing heavy duty material gloves is obligatory!
C - When cutting positon is reached, press button (pos.7) to save the current
angle as cutting position.
- The saved position appears in “Cutting position” box (pos.8).
AIGER CONFIDENTIAL
D000250104
Rev. 01; 05.10.2018
3. Check and confirm that filters are received seamlessly by the grooves of the fluted
6 drum.
1 7
2 4. If the filters appear crushed on the entering end, or do not enter the fluted drum.
3 8 Repeat the procedure again, until no issues can be noticed.
9
4
10 End of procedure.
5 11
12
1.2 Information on adjusting the offset of the fluted drum
The offset of the fluted drum is a precise setting that allows synchronization of the cutting
head with the fluted drum. The purpose of the synchronization is to adjust the position of
the fluted drum grooves so that filter rods coming from the double accelerator are
unobstructedly received.
The setting is performed by a qualified service technician during the initial tests of the
machine.
Procedure:
1. Enter a numeric value in input field for fluted drum offset (pos.10). The entered number
(larger or smaller) must be close to the old value in order to guarantee a precise
adjustment of the offset.
2. Press save button (pos.9) to store the new offset value.
AIGER CONFIDENTIAL
D000250104
Rev. 01; 05.10.2018
4.1.11 Technical setup – Sampling 1/1

7 8
No Description
1 Set degrees for automatic switch ON for Fluted drum sampling [°].
1 11 2 Set degrees for automatic switch OFF for Fluted drum sampling [°].
3 Set degrees for automatic switch ON for V-way valve [°].
2 12 4 Set degrees for automatic switch OFF for V-way valve [°].
3 5 Set degrees for automatic switch ON for Fluted drum waste [°].
4 13 6 Set degrees for automatic switch OFF for Fluted drum waste [°].
5 7 Manual switch ON/OFF for Fluted drum sampling.
14 8 Manual switch ON/OFF for V-way valve.
6
9 Manual switch ON/OFF for Fluted drum waste.
15
10 Manual switch ON/OFF for Fluted drum cleaning.
11 Set the distance between splicing point and V-way reject [mm].
12 Set number of filters rejected per splice [filters].
Set number of NOT detected filters from dynamic rod control sensor
13
10 9 [filters]. The machine stops with an error.
Set coefficient (multiplier) for adjustment of the stroboscopes’ vibration
Description: 14
frequency related to the speed of the machine.
Set coefficient (divider) for adjustment of the stroboscopes’ vibration
The “Sampling” screen contains waste point settings for switching ON/OFF fluted drum 15
frequency related to the speed of the machine.
splicing, v-way valve and fluted drum waste valve, as well as buttons for manual
activation/deactivation; also for fluted drum cleaning.
Fluted drum
Also there are available settings for splicing point and error due to dynamic rod control V-way
sensor not detecting filters.
Sampling Reject
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4.1.12 Technical setup – Sampling 1/1
1 1
2
3
1 4
2
3
No Description (blank page)

1 Set number of filters to be ejected for sampling.
2 Set number of filters to be rejected before the sampling batch.
3 Set number of filters to rejected after the sampling batch.
Set number of filters to monitor for counter error. If the machine is
operating with materials and sensor S58.5 doesn’t detect the set number
4
of filters the machine stops with error message 171 RMM>FILTER
COUNTER FAILURE - S58.5.
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D000250104
Rev. 01; 05.10.2018
4.2 Technical setup – General 1/1
No Description
1 Select machine configuration. (blank page)
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D000250104
Rev. 01; 05.10.2018
4.3 Technical setup – Start program 1/1

16 17
10. Startup reject V-way – Reject valves at V-way start blowing.
11. Start capsule – The insertion wheel is moved into working position (starts inserting
capsules in the tow).
1 12 12. Dynamic rod control – Activates a sensor monitoring the channels of the fluted
2 13 drum for filters presence (before the reject section of the drum).
3 14
22 13. Diameter control active – Diameter control of the machine is activated.
4 15
22
22
5 14. Start Regulation – Line starts using data from the quality assurance system
622 22 (Matrix NeO) to regulate the output product.
22
7 22
22
822 15. End of start program – Start program has been completed. Machine is in normal
9 operation mode. Also serves as upper limit for set values in input fields pos.14. – no
1022 higher value can be entered in pos.13 than the value in “End of start program”
22
1122 18 pos.14.
22
22 16. Filters – set number of filters from startup to complete the step from the start
program.
17. Indicator – Highlighted in green when the step is completed.
18. Start counter – counts the filters from startup of the machine.
General info on Start program screen:
End of description.
In this screen are listed the steps of the start program of the machine.
1. Transport jet on – Air supply for the transport jet is started to take in the tow from
TOM toward the garniture of RMM.
2. Glue gun seam on – Seam glue gun is started when input value in field pos.13 is
reached by the start counter (pos.12).
3. Glue gun inner on – Inner glue gun is started when input value in field pos.13 is
reached by the start counter (pos.12).
4. Lift roller V0 – Roller V0 is lifted.
5. Lift roller V3/V2 – Roller V3/V2 is lifted.
6. Rod cutter – The rod cutter is actuated either manually or automatically by the
operator. The machine pauses on this step of the start procedure until the rod cutter is
actuated.
7. Static rod control active – Activates the optic sensor monitoring the quality of the of
the filter rod before the Diameter Control.
8. Plasticizer on – Plasticizer supply is started.
9. Run up enable – The speed of the machine is increased from Startup to Production.
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D000250104
Rev. 01; 05.10.2018
4.4 Technical setup – Stop program 1/1

17 18 17 18 17. Filters – Set number of filters from stop to complete the step from the start program.
18. Indicator – Highlighted in green when the step is completed.
19. Stop counter – Counts the filters from stop of the machine.
1 12
2 13 End of description.
3 14
4 15
5 16
6
7
8
9
10
11
19
1. Stop waste – The machine starts rejecting filters as soon as the stop program is in
effect.
2. Stop speed active – The speed of the machine is decreased from Production to Startup.
3. Stop main drive – Main drive is stopped.
4. Seam glue pump off – The seam glue pump is stopped.
5. Seam glue gun off – The seam glue gun is stopped.
6. Plasticizer off – The plasticizer supply is turned off.
7. Transport jet off – Air supply for the transport jet is turned off.
8. Lower rollers V3, V1 – Rollers V3 and V1 are lowered.
9. Lift rod cutter – The rod cutter is lifted manually/automatically by the operator.
10. Lower roller V0 – Roller V0 is lowered.
11. Stop capsule – Retreat insertion wheel (stop capsule feeding).
12. Spare – Spare position for stop program sequence.
16. End of stop program – Stop program has been completed. The machine is stopped.
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Rev. 01; 05.10.2018
4.5/4.6 Technical setup – Drives diagnostic 1/1

2 3 4 5
No Description
Fields display drive error number. See additional information on AMK
1
error code by referring to the supplied AMK documentation.
1 2 Drives error status: green – no error; red – error.
3 Drives system ready status: green – ready; red – not ready. (SBM)
Drives active regulation status: green – regulation; red – no regulation.
4
(QRF)
5 UDP connection status: green – connected; red – not connected.
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D000250104
Rev. 01; 05.10.2018
4.7 Technical setup – Status variable 1/1
(blank page)
No Description
1 Go to screen “4.7.1 Status variable – CPU configuration”.
Go to screen “4.7.2 Status variable – CPU periphery module
2
inputs/outputs on/off”.
3 Go to screen “4.7.3 Status variable – Pneumatic inputs/outputs on/off“.
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D000250104
Rev. 01; 05.10.2018
4.7.1/4.7.3 Status variable screens 1/1

General info on “Status Variable” screens:
These screens visualize the hardware inputs and outputs of the PLC and other modules,
allowing for the service technician to monitor them without need of software program
or opening the electrical cabinet.
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D000250104
Rev. 01; 05.10.2018
4.8 Technical setup – AMK PID setup 1/1

1 2
Drives axes are:
- Garniture tape drum

- Knife drive
- Vacuum pump drive RMM
- Fluted drum drive
- Paper tension drive
3 5 - Double accelerator drive
4 6 - Bobbin changer drive
- Douber system drive
ID numbers are:
- P100 – Proportional gain speed control

- P101 – Integral time speed control
No Description - P102 – Diff. time speed control
1 Dropdown menu. Choose drive axis. - P104 – Position loop KV factor
2 Dropdown menu. Choose drive parameter ID number. Procedure for writing value:
3 Axis (1) parameter ID (2) read value.
4 Axis (1) parameter ID (2) write value. 1. Push read button (pos.5).
5 Start reading parameter. 2. Value appears (pos.3).
6 Start writing parameter. 3. Set write value (pos.4).
4. Push save/write value (pos.6).
5. Double check by pressing read button again (pos.5).
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Rev. 01; 05.10.2018
4.9 Technical setup – Display settings 1/1
2 3
(blank page)
No Description
Choose a default language for the HMI. Active languages are fully
1
colored. Inactive languages are grayed out.
2 Save date and time to PLC.
Clean screen button. When the button is pressed, the touchscreen becomes
3
inactive for 30 seconds and can be cleaned.
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D000250104
Rev. 01; 05.10.2018
6.0 Brand Setup – General 1/1

1
Access levels
5
2
4
The following table illustrates the different user groups, access levels and a shortlist
of recommended personnel, that are granted access for configuration and set up.
6
Recommended
Group user: Description:
3 personnel
5. Administrator for the groups
below:
CLIENT_Admin
4. Technician  Service staff
3. Statistic_Admin  Management staff
2. Brand_Admin
1. Operator
4. Setting speed, time durations,
No Description
1 Choose brand from dropdown list. temperatures. Also can adjust
Technician
technical settings related to  Service staff
2 Export all brands to USB stick.
Select a brand from dropdown list to write it to PLC. The machine will BRAND.
3 3. Has permissions to reset the  QA staff
operate with the selected brand. Statistic_Admin
4 Displays currently loaded brand. current statistic.  Management staff
5 Indicates brand number. 2. Has permissions to register  QA staff
6 Set values for the different brand parameters. Brand_Admin
and delete brands.  Management staff
1. Monitors temperatures,
speeds, alarms – cannot
Operator
set/adjust technical parameters.  Operator staff
Change language.
AIGER CONFIDENTIAL
D000250104
Rev. 01; 05.10.2018
6.1 Brand Setup – Admin 1/2

1
11 General information on the functionality of the “Brand setup” screen:
10 6
7
When setting the machine to work with different brands (e.g. King Size; Super Slim),
5 various parameters need to be changed/adjusted for the machine to produce filters
with the intended specifications.
After the adjustment of the parameters is completed and the filter production is
within specifications and approved, then all parameters can be saved cumulatively
2 12 8 under a brand name in screen 6.1.
Refer to the procedures below to learn how to operate on the screen.
9
4 1. Procedure for creating a brand
3
- Press button (pos.2) and enter a brand name (e.g. Brand 1) in the text
field of the dropdown list (pos.1).
- Press button (pos.9) to load the current settings from the PLC. They are
No Description loaded in column “value” (pos.12).
1 Choose brand from dropdown list.
2 Create new brand in dropdown list. - Press button (pos.3) to save the settings to your new brand (Brand 1).
3 Save changes to selected brand.
2. Procedure for editing a brand – “Edit”
4 Edit selected brand parameters.
5 Delete selected brand. - Select a brand from the dropdown list (pos.1) – e.g. “Brand_1”.
6 Export all brands to USB stick.
7 Import all brands from USB stick. - Press button (pos.5) to edit brand parameters.
Select a brand from dropdown list to write it to PLC. The machine will - Edit parameters in column “value” (pos.13).
8
operate with the selected brand.
Load current brand parameters from PLC to HMI. The settings will - Press button (pos.3) to save the edited parameters to currently selected
9 appear on the screen and can be saved as new brand in the dropdown brand (Brand 1).
list.
- Press button (pos.8) write the edited parameters to PLC. The machine
10 Displays currently loaded brand. will operate with the changes in effect.
11 Indicates brand number.
12 Set values for the different brand parameters.
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Rev. 01; 05.10.2018
6.1 Brand Setup – Admin 2/2
1 3. Procedure for selecting a brand

11
10 6 - Press dropdown menu (pos.1) and select a brand (e.g. Brand_2)
7
5 - Press button (pos.8) to write the parameters of “Brand_2” to PLC.
- “Brand_2” will appear as “Loaded brand” (pos.10). The machine now operates
with the parameters of “Brand_2”.
2 12 8
Changing the brands from the dropdown list doesn’t change
9 the settings of the machine. Button (pos.9) must be
4
3 pressed for the changes to take effect in operation.
2.1 Procedure for editing a brand – “Save”
- Select a brand from the dropdown list (pos.1) – e.g. “Brand_1”.

- Press button (pos.9) to load the current settings from the PLC. They are
loaded in column “value” (pos.12) and overwrite the settings of “Brand_1”.
- Press button (pos.3) to save the settings to currently selected brand (Brand
1).
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Rev. 01; 05.10.2018
7.0 Production – Shift log 1/1
1 2 3 4
No Description
1 Name of the current shift.
2 Total produced filters for the current shift.
11
3 Total good filters produced for the current shift.
4 Total rejected filters for the current shift.
5 Name of shift 1 – 4 (previous 4 shifts).
Total produced filters for the shift (data for the previous 4 shifts is
6
displayed).
Total good filters produced for the shift (data for the previous 4 shifts is
7
displayed).
9
Total rejected filters for the shift (data for the previous 4 shifts is
10 8
displayed).
9 Deletes all data records in the log file.
Stop writing in the log file. This allows for opening the log file. The log
10 file can be exported in a .csv file and can be viewed on a PC or other
5 6 7 8 appropriate device.
11 Show/hide trend screen.
12 Graph zoom out.
13 Graph zoom in.
14 Move forward.
12 15 Move backward.
13
16 Go to beginning of shift.
14
17 Stop graph.
15
16 18 Data visualization in trends – total produced, total good, total waste.
17
18
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7.1/7.2 Production – Production archive 1/2 1/1
1 2 3 4 No Description
1 Name of archived shift.
2 Select a shift to view data for.
3 Date of archived shift.
4 Go to second page of “Production archive” screen.
5 Go back to first page of “Production archive” screen.
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Rev. 01; 05.10.2018
7.3 Production – Shifts library 1/1

1 2 3
(blank page)
No Description
1 Enter shift name.
2 Set start time [hh:mm].
3 Set end time [hh:mm].
4 Save changes.
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Rev. 01; 05.10.2018
7.4 Production – Current shifts 1/1

2 3 4 6 7

1 Number of selected shifts.
Choose shift. At least one shift must be selected for the production statistic
2
to work.
3 Displays start time of shift [hh:mm].
4 Displays end time of shift [hh:mm].
5 Save shifts as currently selected.
6 Displays time of last save.
7 Displays the user that performed the last save.
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Rev. 01; 05.10.2018
7.5 Production – Time efficiency 1/1
2
(blank page)
No Description
Time efficiency parameters measured for a period of 24 hours [h, min, s,
1
%].
2 Displaying speed efficiency [% of maximum speed of the machine].
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Rev. 01; 05.10.2018
7.6 Production – Production history 1/1

1 Screen displays statistics for the materials used in production.
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Rev. 01; 05.10.2018
7.7 Production – Production counter 1/1

2
1 3

Displays production statistics for a current period of production (timed by
1 operator or technician). When “RESET ACTUAL” is pressed, the statistic is
reset and is stored under “Old” until the next reset.
2 Press button to reset the actual statistics.
3 Displays the last tracked production statistics.
AIGER CONFIDENTIAL
D000250104
Rev. 01; 05.10.2018
8.0 User administration 1/1

1 2 3 4

1 Click to add new user. Type in the user name.
2 Add a password. A prompt will appear to enter and confirm password.
3 Select a user group.
4 Set log off time for created user (in minutes).
5 Import user administration data from USB drive.
6 Export user administration data to USB drive.
For more information on the access levels, please refer to the

table on 6.1. Brand settings – Brand setup – general page or
Chapter 8 Electrical data, of this Operation manual.
AIGER CONFIDENTIAL

Aiger Flex Rmm-Arcb-mex 21114709-Operation Manual

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Aiger Flex Rmm-Arcb-mex 21114709-Operation Manual

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AIGER FLEX RMM

MACHINE Nr. ARCB-MEX 21114709

Machine Overview – AIGER FLEX RMM

Working product range

Cables cross section

Compressed air supply

The delivered machine might have minor differences due to the

Standard Layout – AIGER FLEX RMM

Standard Floor Loading Diagram – AIGER FLEX RMM

1 Technical data .......................................................................................... 1

5.9.2 Installation .................................................................................. 5.18

6.4.10.1Process of splicing ................................................................. 6.22

6.9.3 Oil fill ........................................................................................... 6.85

8.2.1 Description of the PLC Siemens Simatic S7-300 ............................ 8.3

1.4.2.3 Download the configuration to a file folder of the computer

1.6.1.2 Restore - Lenze 9300 ....................................................... 1.37

3. Operator setup – General ....................................................................... 1.6

7.1/7.2 Production – Production archive 1/2 ............................................. 1.41

1 Technical data ....................................................................................................1.2

1.1.2 Chapter purpose

1.2 Process description of the Rod Module

(fig.1) Process description of the Rod Maker Module

Zone 1 – Paper supply

The current chapter provides following information:

2.1.2 Chapter purpose

This chapter is addressed to the:

2.2 General Safety Information

Personnel requirements - workers must:

2.3 Safety system description

Fig.2 Safety sensors

Code Type Function

S14.3 S14.7 S14.4

Fig.3 Safety sensors

Code Type Function

Safety sensors (rear of the machine)

Fig.4 Safety sensors

Code Type Function

2.3.2 General list of applied safety sensors

No Symbol Type Function

No Symbol Type Function

2.4 General Warnings for work area

Thermal zones Rod module

Fig.5 Dangerous thermal zones on Rod module

Nr Zone Danger aspect Safety measures

Zones with danger of mechanical injury

Fig.6 Areas representing threat of mechanical injury

Nr Zone Danger aspect Safety measures

Nr Zone Danger aspect Safety measures

Zones with danger of electric current

Fig.8 Zones with danger of electric current

Nr Zone Danger aspect Safety measures

Fig.9 Zones with danger of electric current

Nr Zone Danger aspect Safety measures

2.5 Risk factors and hazards areas

Danger of electric current!

Danger of automatic start up!

Danger of mechanical injury – crushing!

Danger of flying particles!

Danger of mechanical injury – cut off!

Danger of mechanical injury – pressing and crumple!

Danger of mechanical injury – pressing of leg or a hand!

Danger of aggressive substances!

Danger of toxic substances!

Danger of welding machine!