Manual

HMI Comfort Panel KP700

English Version – Rev 0.1

Before operating the machine, check the machine components, control
components, emergency stops and safety equipment for damage and proper
function.

Machinenfabrik Ernst Koch GmbH & Co. KG

D-58675 Hemer – Ihmert
Sternstrasse 9
Germany

Phone: +49 - 2372 - 985 - 500

Fax: +49 - 2372 - 985 – 167
Internet: http://www.koch-ihmert.de
E-mail: info@koch-ihmert.de

Morgan-Koch Corporation
330 Tacoma Street, Suite 6A
Worcester, MA 01605
U .S. A.

Phone: +1 - 508 - 793 - 1945

Fax: +1 - 508 - 793 - 2163
Internet: http://www.morgan-koch.com
E-mail: Michelle@morgan-koch.com
Table of contents

KP700

Table of contents

1 General information..............................................................................................5
1.1 Purpose of these operating instructions..................................................................5
1.2 Required basic knowledge......................................................................................5
1.3 Figures.................................................................................................................... 5
1.4 Notes on using the operating instructions...............................................................6
1.5 Warnings and symbols............................................................................................7
1.5.1 Hazard symbols......................................................................................................7
1.5.2 Advice symbols.......................................................................................................7

2 General safety instructions..................................................................................8

2.1 Open-type equipment and Machinery Directive......................................................8
2.2 Operation notes......................................................................................................9
2.3 Industrial use.......................................................................................................... 9
2.4 Target groups of the operating instructions...........................................................10
2.5 Legal notice........................................................................................................... 11

3 SIMATIC HMI Comfort Panel..............................................................................13

3.1 Overview............................................................................................................... 13
3.1.1 Memory concept....................................................................................................13
3.1.2 Internal memory....................................................................................................13
3.1.3 Memory card......................................................................................................... 13
3.1.4 Data consistency...................................................................................................13
3.1.5 System memory card............................................................................................14
3.2 Changing the memory card...................................................................................14
3.3 Front operating elements......................................................................................15
3.3.1 Functions of the system keys................................................................................16

4 Overview: Koch Comfort Panel ........................................................................18

4.1 Function keys (F keys)..........................................................................................19
4.2 System keys.........................................................................................................20
4.3 Function keys for fixed functions...........................................................................20
4.3.1 Function keys F18 and F17 – Control / Operation On / Off....................................21
4.4 Starting of the machine ........................................................................................22
4.5 Function keys F19, F20 and F21 – Changing of nominal speed...........................22
4.6 Function key F24 – Reset (fault acknowledgment)...............................................24

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5 Main Screen........................................................................................................ 25
5.1 Main Screen......................................................................................................... 25
5.1.1 Operating conditions of drawing blocks.................................................................25
5.1.2 Length counter......................................................................................................26
5.1.3 Weight counter......................................................................................................26
5.2 Display of actual values for each block ................................................................28
5.2.1 Function key F1.....................................................................................................28
5.2.2 Function key F3.....................................................................................................29
5.2.3 Function key F5.....................................................................................................30
5.2.4 Function key F7 ....................................................................................................31

6 Menu navigation.................................................................................................33
6.1 Main screen..........................................................................................................33
6.2 Quick menu function keys F11–F15......................................................................34
6.2.1 Quick menu function key F11: Overhead block / OTO block.................................36
6.3 Reseting the OTO wrap counter to zero................................................................37
6.4 Function keys in the Operator menu.....................................................................37
6.5 Function key F16 – Reset of length counter..........................................................39
6.6 Finish device.........................................................................................................40
6.7 Drawing program..................................................................................................41
6.7.1 Drawing program selection....................................................................................41
6.8 Shift counter......................................................................................................... 42
6.9 Length counter .....................................................................................................43
6.10 Menu: Settings......................................................................................................45
6.11 Tuner Roll & Dancer Calibration...........................................................................45

7 Address............................................................................................................... 48

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Chapter 1 General information

1.1 Purpose of these operating instructions

These operating instructions provide information based on the requirements
defined by DIN 8418 for mechanical engineering documentation. This
information relates to the place of use, transport, storage, installation, use and
maintenance.

These operating instructions are intended for:

 users
 commissioning engineers
 maintenance personnel

1.2 Required basic knowledge

General knowledge of automation technology and process communication is
required to understand the operating instructions. It is also assumed that those
using the manual have experience in using personal computers and knowledge
of Microsoft operating systems.

Work at and with the machine is only permitted while observing this
documentation. The operating company is obliged to provide the responsible
personnel with the documentation.

This also applies for changes in personnel, of course. The documentation

belongs to the machine and must be looked after carefully.

The page numbers can be found at the bottom centre of each page.

1.3 Figures
This manual contains figures of the described devices. The figures may differ
from the supplied device in details.

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1.4 Notes on using the operating instructions

The safety instructions given throughout these operating instructions must be
observed.

Notes on the safety of persons and the machine itself are marked with symbols.
The notes must be observed to avoid accidents and material damage.

 General safety instructions are provided in chapter 2. General safety

instructions.
 Notes on special dangers can be found at the beginning of each chapter.
 Safety instructions relating to a special instruction are provided before the
description of the instruction itself.

Moreover, the safety instructions are specially marked in the operating

instructions.

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1.5 Warnings and symbols

1.5.1 Hazard symbols
This symbol indicates an immediate risk of injury or death. Disregarding this
indication can result in serious health problems including life-threatening
injuries.
Danger!

This symbol indicates a potential risk of injury or death. Disregarding this

indication can result in serious health problems including life-threatening
injuries.
Warning!

This symbol indicates a potentially dangerous situation. Disregarding this

indication can result in minor injuries or material damage.

Caution!

Inaccurate compliance or non-compliance with the operating instructions,

working notes or stipulated sequences of work can lead to damage to the
machine.

Live parts!
This sign warns against live parts. Coverings may only be removed by
authorised specialists.

1.5.2 Advice symbols

The advice symbol draws attention to tips and other particularly useful
information in this operating manual. In the interest of an effective machine
operation, all these indications should be observed.

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Chapter 2 General safety instructions

2.1 Open-type equipment and Machinery Directive

.The device constitutes open equipment

The device constitutes open equipment. This means that the device may only
Danger! be installed in enclosures or cabinets which provide front access for operating
the device.

Access to the enclosure or cabinet in which the device is installed should only
be possible by means of a key or tool and for trained and authorized personnel.

Life-threatening voltage when control cabinet is open

If you open the control cabinet, individual areas or components may carry
Danger! life-threatening voltage.

Touching these areas or components can lead to death by electrocution.

Switch off the power supply before opening the control cabinet.

The device may only be operated in machines complying with the Machinery
Directive

Danger! The Machinery Directive establishes, inter alia, the precautionary measures for
commissioning and operation of machines in the European Economic Area.

Non-compliance constitutes a violation of the Machinery Directive. Moreover,

depending on the machine used, personal and material damage cannot be
ruled out.

Only commission the device in a machine complying with the provisions of

Directive 2006/42/EC.

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High-frequency radiation

Unintentional operating situation

Caution!
High-frequency radiation, e.g. emitted by mobile telephones, disturbs the device
functions and can result in malfunctions of the device. This causes personal
injuries and damage to the machine.

Avoid high-frequency radiation:

 Remove radiation sources from the surroundings of the device.

 Switch off radiating devices.
 Reduce the transmission power of radiating devices.
 Note the information regarding electromagnetic compatibility.

2.2 Operation notes

CAUTION
Operator device approved for indoor use only

Using the operator device outside closed rooms can damage the operator Caution!

device.

Only use the operator device indoors.

2.3 Industrial use

The operator device is designed for industrial use. For this, the following
standards are met:

 Requirements regarding interference emission EN 61000-6-4:2007

 Requirements regarding interference immunity EN 61000-6-2:2005

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ATTENTION

Use in residential areas

Caution!
Operator device not intended for use in residential areas

The operator device is not intended to be used in residential areas. Using the
operator device in residential areas can cause interference with radio or
television reception.

If the operator device is used in a residential area, you have to ensure

compliance with limit class B of EN 55011 with regard to radio interference
emission.

Suitable measures to achieve the degree of interference suppression of limit

class B include:

 Installation of the operator device in an earthed control cabinet

 Use of filters in supply lines
Additionally, an individual approval is required.

2.4 Target groups of the operating instructions

 The operating instructions have been written for the operating company
and operators who operate, use and service the machine.
All personnel involved with the machine must:

 have read and understood the operating instructions and safety

instructions,
 wear the necessary protective clothing,
 check the emergency stop keys and other safety equipment for proper
functioning before starting work,
 avoid any actions which cause dangers to anyone's body and health,
dangers for the product or dangers for material property.
 shut down the machine in the event of technical changes and inform the
responsible supervisor or the operating company. The same applies for
irregularities during operation, e.g. for uncommon operating noises etc.

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2.5 Legal notice

Commissioning without an electrician from KOCH is prohibited.
Caution!
The company operating our machines is obliged to train the personnel who
come into contact with the machines. Repeat the training twice yearly, even if
no changes in personnel have occurred.

We reserve the right to make technical changes to improve the product.

The images in these operating instructions may deviate slightly from the actual
design.

Warranty obligations are subject to the corresponding sales contract. The

relevant contractual provisions are neither extended nor limited by the
stipulations in this documentation.

Copyright:

These operating instructions are to be treated confidentially. They have been

designed specifically for the personnel who work at and with the machine. The
operating instructions must not be given to third parties without written
permission from the manufacturer. If necessary, please contact the
manufacturer.

The specifications, text, drawings, figures and other representations

contained are protected by copyright and are subject to further industrial
property rights. Any misuse is punishable.

Reproduction in any type and form – even in extracts – as well as use and/or
disclosure of the contents without the written consent of the manufacturer is not
permitted. Violations incur an obligatory payment of damages. We reserve the
right to make further claims.

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Chapter 3 SIMATIC HMI Comfort Panel

3.1 Overview
3.1.1 Memory concept
The operator devices use the following memory types:

 Internal memory
 Memory card
 System memory card
You can also connect a USB mass storage device via the USB port.

3.1.2 Internal memory

The following data is stored in the internal memory:

 Operating system
 Project file
 Licence keys
 User administration
 Recipes

3.1.3 Memory card

The following data is stored on the memory card:

 Archives
 Backups
 Recipes
 Note

3.1.4 Data consistency

If the operator panel is switched off, consistency of the saved data is only
guaranteed when using a SIMATIC HMI Memory Card of at least 2 GByte.

If a standard commercially available memory card is used, a device switch-off,

e.g. caused by a power failure, can lead to a loss of saved data.

For archives, consistency of the saved data can only be ensured when using
the RDB format.

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3.1.5 System memory card

The system memory card is part of the operator devices' service concept. If you
activate the service concept, all data from the operator device's internal memory
are transferred to the system memory card. If the operator device fails, insert
the system memory card into the replacement device. This way downtimes of
your machine can be reduced to a minimum.

The system memory card is not visible on the operator interface of the operator
device and cannot be used for data storage either. Insert the system memory
card into the slot provided so that it can be recognized by the operator device.

ATTENTION

System memory card inserted in device that is not identical in construction. If

Caution! the system memory card of an operator device is inserted into another operator
device that is not identical in construction, an error message will be displayed.
In case of service, only use a system memory card in structurally identical
operator devices.

3.2 Changing the memory card

The following warning signs are attached to the machine:

The memory cards and system memory cards are secured by a safety sliding
cover. The memory card and the system memory card can be inserted and
removed during operation of the operator device.

ATTENTION
Possible data loss
Caution! If the operator device accesses data on the memory card while the memory
card is being removed, the data on the memory card may be destroyed. Do not
remove the memory card while data is being accessed. Note the relevant
messages on the screen.

Removing the system memory card during an ongoing project

If the system memory card is removed during an ongoing project, the project will
be terminated.

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Figure 1: Slots with safety sliding cover

① Slot for memory card in "SD(IO /

HC)" or "MMC" format.
② Slot for system memory card.
Permissible: SIMATIC HMI Memory
Card of at least 2 GByte
③ Safety sliding cover KP700 Comfort
and TP700 Comfort: two-level

3.3 Front operating elements

The keypad operator device is operated using the system keys and function
keys. The function of the function keys is determined during project planning. If
no project has been started at the operator device, the function keys have no
function.

The figure below shows the front operating elements of the KP700 Comfort:

Figure 2: Front operating elements

1. Display and function keys with LED The number of function keys varies
depending on the display size

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2. System keys – alphanumerical keys

3. System keys – control keys
4. System keys – cursor keys
ATTENTION
Unintentional action possible
Do not perform several operations at the same time. You may execute an
unintentional action.

Do not press more than two keys simultaneously.

Risk of damage to the keyboard.

Using a hard object for operation reduces the lifetime of the key
mechanism considerably.

Only press the keys of the operator device with your finger.

3.3.1 Functions of the system keys

Tabelle 1: 3.4 Functions of the system keys

key or Function
key combination

Changes between upper and lower case:

 LED switched on: upper case
 LED switched off: lower case
Deletes the character to the left of the cursor.

Changes to the next operating object in the TAB sequence.

Changes to the previous operating object in the TAB sequence.

Deletes the character to the right of the cursor.

Switches "Overwrite" mode on or off. When "Overwrite" mode is

switched on, the characters to the right of the cursor are overwritten.

Cancels an action, e.g.:

 Discard input and close dialogue
Executes a command, e.g.:
 Operate key
 Open dialogue or select menu command
 Adopt value and close dialogue

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key or Function
key combination

Moves the cursor, the selected item or a controller into the respective
direction.

Moves the cursor or selected item up one page.

Moves the cursor or selected item down one page.

Press: key over to additional key assignment.

Press and hold: key between upper and lower case.

General control function to be used in key combinations.

General control function to be used in key combinations.

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Chapter 4 Overview: Koch Comfort Panel

The screen of the Koch Comfort Panel KP700 displays actual values of the
machine. The content of the screen may vary depending on the operating
condition of the machine:

On the one hand, the PLC can alter the contents, e.g. to indicate important
events of the machine.

On the other hand, the operator can open various menus in order to set values
or obtain information about the status of the machine.

Figure 3: “Control OFF” screen

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4.1 Function keys (F keys)

The keys F17 to F24 have a fixed function, i.e. they are completely independent
of the actual displayed content of the screen.

The keys F22 and F23 have a function, which is controlled by the configuration
of the machine.

Figure 4: Function keys (F keys)

The function of keys F1 to F8 and F9 to F16 is variable. The function is

described by an icon on the screen close to the function key. Different functions
are available depending on the actual selected menu.

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Figure 5: Function keys (F keys 2)

4.2 System keys

The system keys are used for both navigating through input boxes/menus and
entering/selecting values.

Information on how to navigate to the individual input boxes and enter or select
values can be found in the chapter "3.3 Front operating elements".

Figure 6: System keys

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4.3 Function keys for fixed functions

4.3.1 Function keys F18 and F17 – Control / Operation On / Off
In case the control has been switched off, it can be switched on again by
pressing function key F18. With this key the necessary auxiliary drives such as
motor fans are switched on, frequency converters are pre-charged and the
machine is prepared for normal operation or jog mode. After the control has
been switched on, the screen changes to the display shown in figure 7.

In case the machine is at a standstill, function key F17 can be used to switch off
the control. The auxiliary drives mentioned above will be switched off in this
case.

Figure 7: Main screen

In case the machine is idle for more than 15 minutes, the control will be
switched off automatically to save energy and avoid unnecessary wear and tear.

Before starting the machine, check the safety equipment (e.g. emergency
stops ... - see also safety instructions). Furthermore, make sure that nobody is
put at risk by starting the machine.

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4.4 Starting the machine

In case the control has already been switched on by pressing function key F18,
the machine can be started by pressing function key F18 once again.

To stop the machine, press function key F17 or push one of the stop buttons at
the machine.

4.5 Keys F19, F20 and F21 – change of nominal speed

Each time function key F20 is pressed, the nominal speed is decreased by a
defined decrement (for example 100 fpm)

Each time function key F21 is pressed, the nominal speed is increased by a
defined increment (for example 100 fpm)

A speed change is possible during both standstill and operation. The new value
for the nominal speed is displayed immediately. It is not possible to set the
nominal speed to a higher value than the maximum speed value specified in the
drawing program.

By pressing function key F19 the actual speed can be reduced by a defined
percentage (in general 50 %). This does not affect the nominal speed display
(see figure 8). By pressing function key F19 once again the actual speed
returns to 100%.

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Figure 8: Speed indication

As long as the reduced speed is selected, the LED of function key F19 is
flashing. This function should be used in case of pay-off issues, passing welds,
climbing issues… .

The speed can also be changed directly by entering the requested speed
set-point with the alphanumerical keypad.

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4.6 Key F24 – Reset (error acknowledgement)

In case of an error or a wrong operation the machine will stop and the cause is
displayed in an error message window on top of the actual window.

 The first columns contain the error number (please state the error
number in case you contact our service department), time and date
of the occurrence of the error.
 The last column contains information about the error in plain text.
The "|" symbol is followed by a description of the cause of the error
(circuit breaker, limit switch ...) and the PLC address of the
associated input.
By pressing the "ESC" key you can acknowledge an error and minimize the
error message window. The fault message itself will not be reset. A “!” symbol in
the upper right corner of the screen flashes as an indication that a fault is still
pending.

After the reason for the error message has been cleared, the fault message can
be reset by pressing function key F24. The screen returns to its normal state.

In case several errors are pending simultaneously, the number of existing error
messages is displayed in the upper right corner of the screen. By using the
"cursor up/down" keys you can browse through the different error messages.

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Chapter 5 Main Screen

5.1 Main Screen

The main screen is displayed in case the control has been switched on by
pressing function key F18.

Figure 9: Main screen

The blue area in the upper right corner indicates the actual speed of the
machine in large digits; the smaller ones indicate the nominal speed. The speed
can be modified directly by entering the speed set-point with the alphanumerical
keypad.

5.1.1 Actual values of blocks

column 1: position at the machine

column 2: die diameter
column 3: die deviation in %
column 4: bar-graph of die deviation
column 5: motor torque in %
column 6: bar-graph of motor torque

Figure 10: Example: Actual values of blocks

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5.1.2 Length counter

"?" is followed by the actual length.

"!" is followed by the target length

The machine will be switched off, when the actual

length is reaching the target length

Figure 11: Length counter

5.1.3 Weight counter

"?" is followed by the actual weight.

"!" is followed by the target weight

Since the weight is calculated from the length and

nominal finish diameter, this value is only theoretical
and thus inaccurate in case of deviations of the
finish diameter and the specific weight of the
material

Figure 12: Weight counter

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The operating condition of the machine is indicated by a icon in the lower right
corner:

The machine is at a standstill.

The machine is being jogged. The number displayed in the lower part of the
icon shows the last block that is moving.

The machine is in operation and is increasing the speed (ramp-up condition)

The machine is in operation and the actual speed is constant

The machine is in operation and is decreasing the speed (ramp-down

condition).

Not all of the selected blocks are in operation. The speed is therefore limited as
this usually only happens during string-up the machine

The spool is being positioned.

Limit 1 of the vibration control (spooler or coiler) has been exceeded. The
speed will not be increased any further.

Limit 2 of the vibration control (spooler or coiler) has been exceeded. The
speed will be decreased.

The frequency converters are being initialised and pre-charged. This is a typical
state after an emergency stop. Depending on the converter, this state lasts for
15s to 30s.

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5.2 Display of operating values

In the main display the function keys F1, F3, F5 and F7 are assigned to the
following displays.

5.2.1 Function key F1

By pressing function key F1, the motor speeds are displayed in column 5 and 6
as a percentage of the maximum possible motor speed

Figure 13: Operating value display: motor speed

If the machine is used with very low reductions or if blocks are skipped, the
speed increases towards the wire inlet. Therefore, after the drawing sequence
has been entered, the PLC calculates the maximum speed at which not a single
block will turn faster than 100%. In case of drawing die deviations, however,
individual blocks may turn slightly faster than 100%. A speed buffer of 10% is
provided for this reason. When a motor is turning faster than 100% the bar
graph is changing it's color from green to red.

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5.2.2 Function key F3

By pressing function key F3, the actual torque of the motors is displayed in
column 5 and 6.

Figure 14: Operating value display: torque

Figure 14 shows drawing block 13 in an overload condition. An overload of up to

125% of the nominal load is possible for short periods, particularly when the
machine is starting to run. The bar-graph has a dotted line, which shows the
maximum available torque. The dotted line changes its position at higher
speeds to a lower percentage value.

Figure 15: Relation of available torque and speed

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Figure 15 shows the relation between motor rpm and available torque.

Up to the nominal rpm (name plate value) of the motor, the full nominal torque is
available. Above that value, the torque decreases. Only 50% of the nominal
torque is available, in case the motor is turning with a rpm that is twice of the
nominal rpm.

This is used to achieve a high torque at a lower speeds for large finish
diameters. For smaller finish diameters, however, the lower torque is sufficient
even at higher speeds.

5.2.3 Function key F5

By pressing function key F5, the power of the motors is displayed in column 5
and 6.

Figure 16: Operating value display: motor power

The bar-graph shows the actual power of the motor as a percentage of the
nominal power.

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5.2.4 Function key F7

This display is only available for certain motors and converters. By pressing
function key F7, the temperature of the motors is displayed in column 5 and 6.

In case the first temperature limit is exceeded, the machine will ramp down.

In case the second limit is exceeded, an external fault condition for the
frequency-converter is triggered and the machine will stop with a quick stop.

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Chapter 6 Menu navigation

6.1 User menu

Icons for individual sub-menus and short-cuts are displayed on the screen next
to function keys F1 to F16.

Figure 17: Main screen

Depending on the machine configuration, the function keys may be different

than shown in the figure above. By pressing function keys F11–F12 and F15–
F16 you can access individual sub-menus. Function key F10 is used as a short-
cut and does not open a sub-menu. It serves for toggling between “wire break
control on”, ”wire break control off” and “wire break control mode for stripping
the machine” in this example.

icon key function

F10 Wire break control mode. Pressing the key repeatedly,

selects different modes. No sub-menus will open. The
operating modes are in order of the icons: “wire break
control on”, “wire break control off” and “wire break control
mode for stripping the machine”

F11 Control of the OTO blocks - instructions further down

F15 N/A

F16 Operator menu

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6.2 Quick menu function keys F11–F15

Function keys F11 to F15 are used for accessing sub-menus “quickly”.

These keys are machine specific and therefore can only be accessed
temporarily or not accessed at all, depending on the actual configuration of the
machine.

The meaning of the function keys is explained with an icon next to the function
key

Figure 18: Quick menus

Icon Function

Stripper block. Menu description below

Vertical spooler. Menu description see separate manual

Horizontal spooler. Menu description see separate manual

Small horizontal spooler. Menu description see separate manual

Automatic spool change. Menu description see separate manual

Coiler/Dead Block. Menu description see separate manual

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Overhead block / OTO block. Menu description below

Straightening rollers / descaling unit / wire stretching unit. Menu description

see separate manual

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6.2.1 Quick menu function key F11: overhead block / OTO block
The actual amount of wire wraps accumulated on the overhead block / OTO
block is indicated both graphically as a bar graph and numerically behind the
question mark (?).

The desired number of wraps = target level has to be entered in the input field
behind the exclamation mark (!). A change of the target level also changes the
scaling of the bar-graph. The maximum value of the bar-graph equals 125 % of
the target level.

Figure 19: Quick menu: Overhead block

When the number of wire wraps on the OTO block is falling below the target level, the color
of the bar-graph is changing its color from green to orange. In this case the OTO block will
increase its speed by approximately 15% to reach the target level again.

Figure 20: Level OTO block: orange

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When the number of wire wraps on the OTO block is falling below the programmed
minimum level (typically 40 wraps), the color of the bar-graph is changing its color from
orange to red. The machine will stop. To restart the machine, the accumulation control
switch of the OTO block has to be turned to the off position. The switch has to stay in this
position as long as the actual number of wraps is below the the minimum level. The
machine will run for safety reasons with a reduced speed and the operator should watch
pay-off, snarl switch (loop catcher) and OTO block. After the minimum level has been
reached, the accumulation control switch has to be turned to the on positon again.

Figure 21: Level OTO block: red

6.3 Resetting the OTO wrap counter to zero

Before stringing up the OTO block, the wrap counter must be reset to zero!

To do so, press and hold the red OFF push button at the OTO block and – at
least 0.5 seconds later – turn the accumulation control switch from "ON" to
"OFF".

Icon Function

Use function key F9 to exit the quick menu

6.4 Function keys in the Operator Menu

The operator panel has a tree structure. By pressing function keys F1 to F8,
you can reach different branches of the tree. By pressing function key F9 you
return again to the previous screen.

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By pressing function key F16 in the main screen you will reach the first sub-
menu. The first sub-menu is the operator menu. The operator menu allows the
operator to enter customized settings.

Figure 22: Operator menu

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Functi Function
Icon
on key

Pressing F1 in the operator menu opens the menu for the die
programs

Pressing F3 in the operator menu opens the menu for the spool
settings. For machines without a spooler, this function is disabled.

Pressing F5 in the operator menu opens the shift counter menu.

Pressing F6 opens the calibration menu.

You can calibrate the tuner rolls for a single block

Pressing F7 in the operator menu opens the length counter menu.

Pressing F8 in the operator menu opens the settings menu.

Pressing F9 returns you to the previous screen.

Pressing F13 changes the actual finish device

Pressing F14 changes the actual finish device

6.5 Function key F16 – Reset of length counter

The actual length of the length counter is reset to zero by pressing function key
F16. To avoid zeroing the length counter unintentionally, this function key has to
be pressed and hold until the actual length has been zeroed.

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6.6 Finish device

The selection box in the center of the screen selects the actual finish device for
the operation of the line. Typically, this may be a stripper block, a dead block or
a spooler. The icons of the selection window is adapted to the actual
configuration of the machine. If no reasonable selection can be made (for
example: machine with a single stripper block only) the selection box is not
available.

Figure 23: Current condition: operation with dead block

Switch on dead block operation

Switch off stripper block operation

Figure 24: Current condition: operation with stripper block

Switch on stripper block operation

Switch off dead block operation

The finish device can be changed only, when the machine is not running!

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6.7 Die program

Pressing function key F1 in the operator menu opens the selection menu for the
die program.

6.7.1 Die program selection menu

Figure 25: Die program selection

Selection table:
1st column: program number
2nd column: rod diameter and finish diameter
3rd column: diameter block by block

Icon Function

Scroll one page up

Scroll one line up

Scroll one line down

Scroll one page down

Return to previous page

Edit die program

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Icon Function

Save programme

Transfer to PLC

6.8 Shift counter

By pressing function key F5 in the operator menu you enter the menu for the
shift counters.

The shift counters counts length and weight separately, so that a change of the
finish diameter does not distort the result of the weight counter.

During a shift change all values in the column "actual period" are copied to the
column "last period" depending of the selection, when the copy process should
actually happening (selections available: daily, weekly or monthly). At the same
time all values in the column "actual period" are set to zero. The line with the
active shift is highlighted green.

Figure 26: Shift counter

Icon Function

Return to previous screen

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6.9 Menu: Length Counter

Pressing F7 in the operator menu will open the length counter menu.

Figure 27: Length counter menu

The length counter calculates depending of current speed and deceleration time, when the
machine has to ramp down to reach the exact target length. This guarantees that each spool
has the same length without having the operator to correct the target length manually in case of
changes of the actual speed.

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Figure 28:

The line marked “-1” indicates the length and weight of the last spool.

The line marked “-2” indicates the length and weight of the second-last spool.

The line marked “-3” indicates the length and weight of the third-last spool.

The line marked “∑- x” indicates the total length and weight of the fourth-last
and all spools previous the fourth-last spool. This line also includes the number
of produced spools.

The line marked “∑” indicates the total, including the spool in production. In this
case the spool in production is still classified as a scrap spool due to the fact
that it hasn’t yet reached the defined threshold level. This will change as soon
as the filling percentage is higher than the threshold level.

However, the operator can change the classification of the last three spools
manually in case that there was a problem with the quality of the produced wire,
for example scratches, diameter out of tolerance …

Using the function keys F14, F15 and F16 the classification can be changed in
both directions, i.e. spools that are not sufficiently filled can be re-classified from
“scrap” to “good”.

When starting a new job, the job counter can be reset to zero by pressing the
keys F11 and F12 simultaneously.

The password for “User 1” has to be entered for any changes of the last two
operations

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6.10 Menu: Settings

The menu “Settings” is selected by pressing function key F8 in the operator

menu

In general no entries are possible in this menu. The settings menu provides only
access to other menus.

6.11 Menu: Tuner Roll & Dancer Calibration

By pressing function key F6 in the menu “Settings” you select the menu “Tuner
Roll & Dancer Calibration”. This menu allows you to calibrate all tuner rolls and
dancers at the same time. A password has to be entered first before getting
access to this menu.

Follow the following procedure step by step to calibrate all tuner rolls and
dancers at the same time:

1. Press function key F6

2. The “Logon” window will pop up - you are asked for user and password
2.1. Enter User: 6
2.2. Press the key “TAB”
2.3. Enter Password: 98501

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2.4. Press the key “TAB” to select the “OK” button in the logon window
2.5. Press the key “ENTER”
2.6. Remark: You have to press and hold the keys of the alphanumerical
keyboard to select numbers for user and password. If you do not hold
the key, a character and not the appropriate number will be selected.
3. Press function key F6 to enter the menu "Tuner Roll & Dancer Calibration"

4. Calibration for the “wire tight position”

4.1. Release the air for the air cylinders of all tuner rolls and dancers.
4.2. Move tuner rolls and dancers to the “wire tight position”
4.3. This means (see also the picture above)
4.3.1. for a tuner roll: move the tuner roll all the way towards the capstan
4.3.2. for a “regular dancer” at a spooler or dead block: move the moveable
pulley all the way towards the stationary pulley, so that both pulleys are
tight together
4.3.3. for a “S-dancer” at a dead block: move the moveable pulley all the way
towards the wire drawing machine
4.4. Make sure that dancers and tuner rolls stay in these positions
4.5. Press function key F6 to calibrate all tuner rolls and dancers for the “wire
tight position” at the same time.
5. Calibration for the “wire loose position”
5.1. Maintain air pressure to the air cylinders of tuner rolls and dancers.
5.2. Dancers and tuner rolls should stay in the “wire loose position” as long as
the air pressure is sufficient
5.3. This means (see also the picture above)
5.3.1. for a tuner roll: the tuner roll is all the way away from the capstan
5.3.2. for a “regular dancer” at a spooler or dead block: the moveable pulley is
all the way down/out, so that both pulleys are apart
5.3.3. for a “S-dancer” at a dead block: the moveable pulley points all the way
towards the dead block
5.4. Make sure that dancers and tuner rolls stay in these positions
5.5. Press function key F4 to calibrate all tuner rolls and dancers for the “wire
loose position” at the same time.

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Chapter 7 Address

Machinenfabrik Ernst Koch GmbH & Co. KG

D-58675 Hemer – Ihmert
Sternstrasse 9
Germany

Phone: +49 - 2372 - 985 - 500

Fax: +49 - 2372 - 985 – 167
Internet: http://www.koch-ihmert.de
E-mail: info@koch-ihmert.de

Morgan-Koch Corporation
330 Tacoma Street, Suite 6A
Worcester, MA 01605
U .S. A.

Phone: +1 - 508 - 793 - 1945

Fax: +1 - 508 - 793 - 2163
Internet: http://www.morgan-koch.com
E-mail: Michelle@morgan-koch.com

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