03-F02200 - Operator Panel - en

CONTENT
CHAPTER 1
TOUCH SCREEN INSTRUCTIONS 1
1.1 TOUCH SCREEN 1

1.2 LIST OF CONTROLS 1
1.3 FOREWORD 3
1.4 SAFETY STANDARDS/WARNINGS 4
1.5 TOUCH SCREEN BROWSING 5
1.6 MENU BAR 6
1.7 TOP STATUS BAR 8
1.8 PANEL LOGIN 9
1.9 LOGOUT 9
1.10 EXAMPLE OF VALUE MODIFICATION 10
CHAPTER 2
PARAMETERS 11
CHAPTER 3
RECIPES 15
CHAPTER 4
ALARMS - MESSAGES 21
4.1 ALARM HISTORY 22

4.2 OPERATING FAULTS 23
4.3 SAFETY SYSTEMS 24
4.4 EMERGENCY BUTTON 26
4.5 ERROR MESSAGES AND RELATIVE SOLUTIONS 27
4.6 ALARM MESSAGES OF THE LABELLING MACHINE AND
RELATIVE SOLUTIONS 37
CHAPTER 5
PRODUCTION 39
5.1 SETUP 41
5.2 VALVES LAYOUT 44
5.3 MANUAL CONTROLS 45
5.4 P.I.D. 47
Instruction manual - Content - 1

5.5 ELECTRIC AXLES 48
5.6 SELECTING THE PROGRAM 51
CHAPTER 6
CONTROL PANEL 53
6.1 TANK HEIGHT ADJUSTMENT 54

6.2 CAM REGULATION 54
6.3 RINSING MACHINE REGULATION 55
6.4 CAPPING MACHINE HEIGHT ADJUSTMENT 55
6.5 LIST 56
6.6 EXTERNAL DEVICES 56
6.7 ACCESSORIES 57
6.8 EXTERNAL WASHES 57
CHAPTER 7
DIAGNOSTICS 59
7.1 EXCHANGE SIGNALS 59
CHAPTER 8
SERVICE 61
8.1 SERVICE - SYSTEM LOGS 62

8.2 SERVICE - BACKUP / RESTORE 63
CHAPTER 9
SCHEDULED MAINTENANCE 65
CHAPTER 10
SETUP MIXER 67
10.1 MIXER SETTINGS 67
2 - Content - Instruction manual

TOUCH SCREEN INSTRUCTIONS
1.1 TOUCH SCREEN
Below is the table of each machine control panel with the explanations of the related
command, control and emergency buttons
fig.1
1.2 LIST OF CONTROLS
Selectors
KEY SELECTOR
Enables manual or automatic machine operation.
Buttons
MACHINE RUNNING (White)

It activates the machine when pressed.
Operator Manual - Chapter 1 - 1

MACHINE STOP (Black)

It stops the machine when pressed.
RESET - EMERGENCY (Blue)

Resets operation after a stop.
CONTAINERS ENTRANCE ENABLING

The button is used to enable container infeed and start
production; the machine must be in AUTOMATIC mode
EMERGENCY STOP
Complete machine stop. The power supply and the compressed air flow are
interrupted, thus blocking all the machine parts.
Transponder
Transponder read / write RFID unit
Jog
The machine is equipped with a mobile-jog push-button panel on which

a pulse start button is installed; if pressed this allows
step machine movement.
2 - Chapter 1 - Operator Manual

1.3 FOREWORD
Position
Control box
Execution
Control unit with images:
- for service
- for diagnosis
- images of anomalies
- with direct access for operators
Images with displays, buttons
Purpose
Controlling the machine
Displaying production data, operating conditions and anomalies.
To adjust the machine.
Control
Touch the buttons
Purpose of this document:

This document describes the control elements required for operators during normal use.
Have changes performed by qualified and authorised technicians only, for example:
by KOSME service technicians
by your staff, trained by KOSME

1.4 SAFETY STANDARDS/WARNINGS
While the machine is running, comply with:

• Safety standards and precautions
• General warnings
They are contained:
• in the use and maintenance documentation
The "Safety" chapter is aimed at protecting people and the machine.
Therefore, read this chapter to prevent injuries and damage!
Here you can find guidelines to be observed during subsequent operations, for example
safety standards and precautions.
• The following is a list of buttons displayed on the Touch screen pages.

• The touch screen is provided with the displays and buttons of functional units used to con-
trol the machine.
• The buttons are displayed with a symbol.
• The functional units and buttons selected are highlighted with colours.
ATTENTION: Incorrect touch screen use

Danger for people and for the machine
• Do not press the buttons at random.
• Only use the touch screen after becoming familiar with its functions.
• Do not touch the buttons with sharp or hard objects (e.g. screwdriver).
• Using work gloves may cause control errors.
ATTENTION: Unauthorised access to higher levels

Danger for people and for the machine
• Always perform login before starting to work on the touch screen.

• Never leave the touch screen unsupervised when a user has logged in.
• Always personally log off after completing work on the touch screen.
• Using video buttons for calibration or adjusting the machine is only permitted to users with
higher access level (e.g. Maintenance, installation technicians, administrators). (The rele-
vant video buttons are locked for the "Operator" group of users).
• Have these operations only carried out by skilled and authorised technicians, e.g. techni-
cians of the KOSME support service or personnel of your company instructed by KOSME.
• The control elements that are not described in these instructions must only be used by the
technicians of the KOSME support service or by personnel of your company instructed by
KOSME.

1.5 TOUCH SCREEN BROWSING
TOP STATUS BAR
MENU BAR
The operator panel has been designed to precisely manage all the operational functions of
the machine. To consult the menus, just touch the relative icon. There are two STATUS
BARS on each page: the top one and the bottom one. The page name of reference is on the
left of the top status bar, while the user protection level is on the right. The recipe in progress
can be viewed on the bottom bar.

1.6 MENU BAR
Below is the list of the icons featured in the menu bars of the operator panel, with relevant
descriptions:
PARAMETERS
The values set by the technician are displayed
RECIPES
Recipes can be viewed, created and/or deleted
PRODUCTION
CONTROL PANEL
DIAGNOSTICS
From this sub-menu it is possible to manually move the
axes and to view possible ACOPOS error messages.
SERVICE
IMPORT & EXPORT of parameters and recipes to and
from a USB drive are managed on this
sub-menu.
ALARMS AND MESSAGES

Messages and alarms can be viewed.
SCHEDULED MAINTENANCE
MIXER SETUP
KRONES PANEL
CIP

CONTAINERS ENTRANCE ENABLING
MACHINE RESET
OPEN/CLOSE SAFE GUARDS
DUMMY BOTTLES
DOUBLE TOUCH ENABLING BUTTON ON THE

MULTI TOUCH PANEL
SHIFT REGISTER

1.7 TOP STATUS BAR
1 2 4 6 8
3 10 5 7 9
1 Recipe in use
Messages row (machine status): indicates anomalies and current
2
warnings. Press the text to access the Alarms / Warnings screen.
3 Program in use.
4 No. of pieces produced (partial count).
5 Current speed (in bph).
6 Indication of the user currently logged in and the type currently in use.
7 Indication of the current date and time.
8 Language change.
Print button of the panel: when a USB pen drive is inserted in the panel, press
9
the button to automatically obtain print-screens of the active panel page.
10 Manual/Automatic mode.

1.8 PANEL LOGIN
To LOGIN in the control system, it is not necessary to have a

USERNAME and PASSWORD. Access is immediate at the lowest authorisation level (Op-
erator level).
If however you wish to access with a higher operative level it is required to log in with correct
USERNAME and PASSWORD into the panel.
The user levels already set on the panel are:
. OPERATOR
. ADMINISTRATOR
. MANUFACTURER'S TECHNICIAN
ATTENTION: Access level abuse

These instructions are designed for users with "Operator" access authorisation.
To prevent any machine malfunctioning:
Always directly perform personal login before performing operations on the
touch screen.
Always keep under control the touch screen while logged on.
1.9 LOGOUT
The LOGOUT button is located in the top status bar on the main page of the panel.
Press the “Log Off” button and you switch to the basic au-
thentication level: Operator level
1. OPERATOR
2. END OF THE LINE
3. MAINTENANCE OPERATOR
4. ADMINISTRATOR
5. TECHNICIAN

1.10 EXAMPLE OF VALUE MODIFICATION
If, having such permission, you wish to modify the values of the parameters or recipes, the
procedure is shown below. Selecting any value accesses the edit page regarding the selected
parameter.
To modify the selected parameter, just enter the new

value in the numeric keypad and then press the OK
button to confirm.
KEYS 1/0
Used to control parts of the machine, functions or to enable processes.
To enable press I --> ON.
To disable press O --> OFF.

PARAMETERS
PARAMETERS
By pressing the indicated icon, you access the machine's parameter management page. On
this page the operator can view the configuration values set previously and modify the pa-
rameters. All the parameters are memorised on the panel.
1. Sensor Level Regulation;

2. Pressure Sensor Regulation;

PARAMETERS
3. Sensor Height Regulation;
4. Start/Stop Machine Sensors Settings

PARAMETERS
5
6
5. Settings - Filler Washing Programs;
6. Settings - Filler Washing Programs;

PARAMETERS

RECIPES
RECIPES
By pressing the indicated icon, you can access the page where new recipes can be created
and existing recipes modified or deleted. All you need to do is select the desired format in
the FORMAT main screen, then press the TRANSFER key to activate it.
ATTENTION! It is not possible to transfer the selected format during produc-

tion.
Each recipe has a unique name. The name of the recipe in use is visible in the upper bar of
the panel.

RECIPES
Create a new recipe
Permanently eliminates a recipe from the drop-down list
Copy an existing recipe
Edit an existing recipe
Transfers the values of the recipe selected in the drop-down list to the PLC.
The operation is not allowed if the machine is moving.
After the transfer, the selected recipe will be processed.
The actual recipe change will be seen because the name of the current
recipe viewed on the upper bar of the panel will change.

RECIPES
SELECT RECIPE TO BE USED
All you need to do is select the desired recipe in the RECIPES main screen, then press the
LOAD key to activate it.
1 Selected recipe.
2 Loading the selected recipe (recipe enabling)
ATTENTION! The selected recipe cannot be loaded if the machine is moving

(stop the machine and load).

RECIPES
MODIFY EXISTING RECIPES
In the main RECIPES screen, select the recipe you wish to modify, then press the MODIFY
key.
3
4
3 Selected recipe
4 Recipe modification key
Check the values already present and modify them as needed (the parameters are
described in the previous paragraphs).

RECIPES
RECIPE COPY
In the main screen, select the recipe you wish to duplicate, then press the COPY key.
5 Selected recipe
6 Key for recipe copy
Insert the new recipe name and confirm.
This operation will copy all the values of the original recipe.

RECIPES
NEW RECIPE INSERTION
The NEW recipe procedure allows you to create a recipe from the start.
Press New to begin the wizard
RECIPE NAME INSERTION
To enter the new recipe name press the RECIPE NAME field and enter the new name using
the alphanumerical keyboard displayed on the video

ALARMS - MESSAGES
ALARMS - MESSAGES
Press ALARMS for the complete list of alarms and messages.
By pressing the indicated icon, you can access the alarms display and service messages
page. La page-écran affiche les messages d’alarme et d’avertissement qui gênent ou qui
pourraient gêner le fonctionnement correct de la machine.

ALARMS - MESSAGES
4.1 ALARM HISTORY
On this page you can view the history of alarms and warnings of the machine.
Press to adjust the alarms history register.
Press to filter data regarding the history

register of triggered alarms.

ALARMS - MESSAGES
4.2 OPERATING FAULTS
Operator level : Qualified Electrical Maintenance Operator

Manufacturer’s Technician
Qualified technicians only must carry out operations to eliminate alarms that
personnel are not trained for.
The machine’s electrical system comprises high quality electrical and mechanical compo-
nents, therefore it is long-lasting and reliable over time.
Despite the aforesaid, operating faults may occur due to malfunction of electrical compo-
nents.
Below is some advice on how to solve these problems. For more detailed information,
please contact the Manufacturer’s Assistance Service.
Before intervening on electric parts or control on the machine:

• Stop the machine
• Disconnect the power supply from the panel by turning the main power switch to a disabled
position marked by the symbol ”O”.
• Secure the selector so that the machine cannot be started. Comply with all safety regula-
tions.
.

ALARMS - MESSAGES
4.3 SAFETY SYSTEMS
Should an anomaly occur, the machine is equipped with safety systems for its immediate
stop.
SAFETY SYSTEMS
USEFUL ADVISE FOR THE OPERATOR SAFETY AND MACHINE PROTECTION

The machine design and construction will be performed according to the regulations and
consequently to the safety criteria required, with regard to every specific case.
• The operator must be able to see and, if necessary, act on the control board during ma-
chine operation. It must also be possible to verify correct product flow, instant by instant.
• Also remember format changeover operations. It is necessary, if not obligatory, for the ma-
chine operator to be always on its front part. Namely where the control panel with the access
controls to the machine features is located.
• Each adjustment operation must be carried out by one person only, and access to the ma-
chine by unauthorized people during this operation is forbidden.
• Do not, for any reason, change the machine parts to adapt further devices. The manufac-
turer does not assume any responsibility on the possible consequences for malfunctioning
of the above.
• Clean the machine coverings and panels with a soft cloth soaked in a light cleansing solu-
tion. IT IS FORBIDDEN to use solvents like alcohol or petrol.
• Personnel having 3, 4 qualification must intervene on the electric system or inside the elec-
trical panel.
• NEVER perform any operation when the machine is running. Turn the switch to turn ma-
chine off should it block for any reason and contact the maintenance manager. We recom-
mend always keeping the space next to the machine clean and adequately lit.
• Ensure to properly tighten work clothes sleeves at wrists.
• Do not wear ties or scarves that may become trapped in the machine moving parts.
• Always use work shoes in line with the accident-prevention standards of all countries.
• Always check emergency buttons work by directly activating each work cycle start.

ALARMS - MESSAGES
LIGHT COLUMN
PLx EMERGENCY
(RED)
The luminous column lights up/flashes in
WARNING
certain working/anomaly conditions.
(YELLOW)
NORMAL COND.
(GREEN)
RESET
For the meaning of the luminous signals (BLUE)
see the table below.
SIREN
LUMINOUS SIG- MEANING NOTE

NALISATION
Red, lit Error signalisation. The anomaly is displayed
Anomalies with on the touch screen
machine stop.
The machine is not ready to
operate until the
anomaly is eliminated.
Yellow, lit Warning signalisation. The anomaly is displayed
Anomalies have occurred on the touch screen
during operation, e.g.:
no containers in the
infeed area, accumulation of
containers in the outfeed area
Green, lit The machine works in No anomaly signalled
production operation
Blue, lit A reset is requested
Access the DIAGNOSTIC - SIGNALISATION TEST screen on the control panel,

to check the beacon and siren operation.

ALARMS - MESSAGES
4.4 EMERGENCY BUTTON
As previously said, the emergency button is located on the control board.

Always remember the emergency buttons must only be used in a real emergency, as they
can jeopardise personal safety or machine protection. Do not, for any reason, use the emer-
gency buttons to stop production normally, as this type of machine stop entails a long new
re-starting procedure of the machine itself; this negatively influences end of day production.

ALARMS - MESSAGES
4.5 ERROR MESSAGES AND RELATIVE SOLUTIONS
The icon next to the arrow lights up when an alarm is triggered and is displayed on the cur-
rent screen Pressing the icon displays the alarms.
MESSAGE CAUSE AND POSSIBLE SOLUTION

The sensor signals the presence of excessive accumulation of bot-
tles downstream of the machine’s discharge conveyor.
DOWNSTREAM ACCUMULATION Eliminate the cause that prevents discharge of the bottles from the
machine.
Production restarts automatically.
The sensor signals the presence of excessive accumulation of bot-

tles downstream of the reject conveyor.
REJECT ACCUMULATION Eliminate the cause that prevents discharge of the bottles from the
machine.
Production restarts automatically.
FFU FAN ALARM FROM LAMINAR The laminar flow filters are dirty.
FLOW Read the laminar flow user manual and clean the filters.
Alarm received from the expeller after an error signalling too many
EXPELLER ALARM
consecutive rejects or general operation alarm
Check operation of the product inlet valve

(maybe it does not close properly).
MAXIMUM LEVEL ALARM Then empty the tank until a value below the maximum level is
reached.
Press RESET to restart production.

(maybe it does not open properly or insufficient product reaches it).
MINIMUM LEVEL ALARM
When the tank reaches a value above the minimum level, production
restarts automatically.
DOWNSTREAM REJECT SYSTEM Error from the control system (e.g. level control, weight control, cap
ALARM control) on the outlet conveyor.
Close the indicated safety door.

DOOR OPENING 1, 2, 3, ....
The machine’s guards are open.

Check the open guards from the CONTROL PANEL screen on the
ATTENTION OPEN GUARDS
touch screen and close them.
Check the sensors that control the position of the wash tub, since its
WASH TUB SENSORS FAILURE
position is not detected correctly.
In the event of two machines connected in synchronism, the Slave

machine has the entrance gate closed.
SLAVE ENTRANCE BLOCKAGE
Eliminate the cause of the block.
The tank’s cam is not in the correct position.

CAM OUT OF POSITION
Contact the Manufacturer’s Assistance Service.
There are blocked containers in line with the internal worm screw.
TRIGGERED INTERNAL WORM
Remove the jam. Phase the worm screw
SCREW

ALARMS - MESSAGES
DISCHARGE ON SIGNAL FROM THE Signal from the control panel of the conveyor.
CONVEYOR The entrance gate closes, the machine keeps running and empties.
(EMPTYING IN PROGRESS) It restarts when it receives the command from the conveyor panel.
One of the shutters has decreased the filling flow (caused by dirt,
nozzle started incorrectly, etc.) and is not able to fill the container
EXCESSIVE CONSECUTIVE REJECTS
completely.
OF A CELL DUE TO EXCESSIVE
SPEED
Find the defective shutter by checking the Production page on the
Touch Screen (refer to the relative manual).
EXCESSIVE CONSECUTIVE The filling valves are unable to fill the containers completely. De-
WEIGHT REJECTS crease the production speed.
In the event of two machines connected in synchronism, the emer-

gency button has been pressed on the Slave machine.
SLAVE MACHINE EMERGENCY
Eliminate the cause of the emergency.
CONVEYOR EMERGENCY UP- Conveyor belts blockages in machine entrance.

STREAM OF THE MACHINE Reset conveyor operation, press RESET to restart production.
Excessive level of product in the tank.

Check operation of the product inlet valve and pipes. In MANUAL
PRODUCT EMERGENCY
mode, empty the tank until it reaches the correct level.
Check the components connected in Profibus from the panel.

COMMUNICATION ERROR
The solenoid valve situated under the rinsing machine does not re-
RINSING MACHINE DISCHARGE SV
spond correctly to opening/closing commands.
NON IN POSITION
Check correct operation.
Alarm from the filling system’s PLC.

ELECTRONIC FAULT
One or more machines downstream are stopped.

END LINE NOT READY As soon as the problem is solved, press RESET and restart produc-
tion.
The container inlet photocell has detected a container that has tipped
FALLEN BOTTLE
over. Remove the container, press RESET and restart production.
The machine was stopped after detection of a bottle not filled correct-
BOTTLE WITH NON-COMPLIANT
ly. Remove the container, press RESET and restart production.
WEIGHT
(For machines without a reject conveyor)
The inlet photocell has detected a bottle that is not oriented correctly.
BOTTLE NOT ORIENTED Remove the container, press RESET and restart production.
(In lines with an orienting machine).
The probes on the rinsing machine burette indicate the very low level
LOW LEVEL IN BURETTE of water or washing liquid.
RINSING MACHINE Fill the burette until reaching the correct level.
The probes on the rinsing machine burette indicate the very high lev-
el of water or washing liquid.
MAX BURETTE LEVEL Check operation of the washing liquid inlet valve.
Empty the burette until reaching the correct level.
Check the level indicated on the control panel of the Touch Screen.
LEVEL BEYOND SET Check operation of the product inlet valve and pipes. Empty the tank
THRESHOLD until a value below the maximum level is reached.

ALARMS - MESSAGES
The tank has reached an accumulation-limit time and the product is

reaching the height of the internal cannula.
ABOVE CANNULA LEVEL ALARM
Lower the level of the tank set on the Touch Screen.

LEVEL BELOW THE SET (maybe it does not open properly or insufficient product reaches it).
THRESHOLD When the tank reaches a value above the minimum level, production
The pressure gauge in the pneumatic panel signals insufficient pres-

NO AIR IN JACKS sure. Check the compressed air power supply system.

NO NITROGEN sure. Check the nitrogen power supply system.
The water inlet pressure gauge signals insufficient pressure; check

NO WATER PRESSURE the system.

NO CO2 PRESSURE - STERILE AIR sure. Check the sterile air-CO2 power supply system.

NO AIR sure. Check the compressed air power supply system.
The pressure gauge signals insufficient pressure. Check the sorter

NO CAPS SORTER AIR air feeding system.
The pressure gauge signals insufficient pressure. Check the capping

NO CAPPING MACHINE machine air feeding system.
The sensor situated at the machine’s entrance signals insufficient ac-

cumulation of bottles before the worm screw.
NO BOTTLES
Check the reasons; production restarts automatically as soon as a
sufficient accumulation of bottles has been reached.

(maybe it does not open properly or insufficient product reaches it).
NO PRODUCT
When the tank reaches a value above the minimum level, production
NO CAP STOPPERS ON Check the reason (cap stopper blocked in the drain pipe, empty sort-
CANAL er, etc.). Press RESET to restart production.
Add a sufficient amount of caps in the caps elevator hopper.

NO CAPS CHARGER CAPS
Check the reason (caps blocked in the drain pipe, empty sorter, etc.).
NO CAPS ON CANAL
The caps do not reach the caps-release starwheel despite being on

the drain pipe.
NO CAPS ON STARWHEEL
Check the caps release system.
When regulating the height, the tank has reached the maximum lev-
MAXIMUM TANK HEIGHT REACHED el.

ALARMS - MESSAGES
When regulating the capping machine height, the capping machine

MAXIMUM CAPPING MACHINE
has reached the maximum level.
HEIGHT
When regulating the height, the tank has reached the minimum
MINIMUM TANK HEIGHT
level.
REACHED
When regulating the capping machine height, the capping machine

MINIMUM CAPPING MACHINE
has reached the minimum level.
HEIGHT
MANUAL MODE The selector on the control panel is set to “MAN”.
The disconnecting switches of the conveyors are OFF (0).

DISABLED CONVEYOR MOTORS
Turn the disconnecting switches ON (1) to enable them.
The disconnecting switches of the inlet conveyors are OFF (0).

DISABLED INLET CONVEYORS
The disconnecting switches of the outlet conveyors are OFF (0).

DISABLED OUTLET CONVEYORS
The automatic lubrication system signals a malfunction (e.g. no

grease).
GREASE PUMP STOPPED Check the error code shown on the display of the grease pump.
Check the pump’s manual.
The canal correction pressure of the valve is incorrect.

RING PRESSURE BELOW THE SET
Check the air feed pressure.
THRESHOLD
The tank cannot reach the pressure set on the panel. Set the pres-
sure regulator correctly in the pneumatic panel and check for any
PRESSURE OUT OF TOLERANCE
leaks.
The tank cannot reach the pressure set on the panel. Set the pres-
TANK PRESSURE BELOW THE SET sure regulator correctly in the pneumatic panel and check for any
THRESHOLD leaks.
Set the pressure regulator correctly regarding the foamer situated

FOAMER PRESSURE SWITCH under the capping machine.
PROBLEMS WITH THE MACHINE UP-

One of the machines upstream of the line has stopped.
STREAM
PROBLEMS WITH THE MACHINE

One of the machines downstream of the line has stopped.
DOWNSTREAM
The number of containers set in production with count-down has

PRODUCTION COMPLETED
been reached.
The front emergency button of the filling machine has been pressed.
EMERGENCY BUTTON
Remove the cause of the stop.
FRONT FILLING MACHINE
The front emergency button of the capping machine has been

EMERGENCY BUTTON pressed.
FRONT CAPPING MACHINE Remove the cause of the stop.

ALARMS - MESSAGES
The rear emergency button of the filling machine has been pressed.
EMERGENCY BUTTON
REAR FILLING MACHINE
The rear emergency button of the capping machine has been

EMERGENCY BUTTON pressed.
REAR CAPPING MACHINE Remove the cause of the stop.
The emergency push button on the inlet conveyor has been pressed.
EMERGENCY PUSH BUTTON ON
RC INLET CONVEYOR
The emergency push button on the panel has been pressed.

EMERGENCY PUSH BUTTON ON THE
PANEL
The stop push button on the control panel has been pressed.
STOP PUSH BUTTON
Restart production.
One or more emergency push buttons have been pressed. Release

K14.10G EMERGENCY PUSH BUT-
the buttons and press RESET.
TONS PRESSED
The motor of the air suction fan in the machine has triggered an error.
FILLING MACHINE: INSUFFICIENT
Check if the fan is clogged.
SUCTION
OPEN CAP STOPPERS SORTER The caps sorter door is open; close the door.
GUARDS Press RESET to restart production.
The caps sorter door is open; close the door.

OPEN CAPS SORTER GUARDS
The external worm screw is blocked. Remove the cause of the block
TRIPPED EXTERNAL WORM SCREW and phase the worm screw by turning it until it clicks.
The infeed worm screw is blocked. Remove the cause of the block
TRIPPED INFEED WORM SCREW and phase the worm screw by turning it until it clicks.
The capping machine infeed worm screw is blocked. Remove the

TRIPPED CAPPING MACHINE INFEED cause of the block and phase the worm screw by turning it until it
WORM SCREW clicks.
The rinsing machine/blowing machine infeed worm screw is blocked.

TRIPPED RINSING MACHINE/BLOW- Remove the cause of the block and phase the worm screw by turning
ING MACHINE WORM SCREW it until it clicks.
The capping machine infeed worm screw is blocked. Remove the

TRIPPED CAPPING MACHINE WORM cause of the block and phase the worm screw by turning it until it
SCREWS clicks.
The inverter of the motor indicated in the electrical panel signals a

malfunction.
TRIPPED INVERTER xxx Identify the inverter by referring to the wiring diagram.
Check the indicated error code from the inverter’s user manual.

ALARMS - MESSAGES
The inverter of the conveyor motor upstream in the electrical panel

signals a malfunction.
TRIPPED UPSTREAM CONVEYOR
Identify the inverter by referring to the wiring diagram.
INVERTER
The indicated inlet conveyor motor inverter in the electrical panel sig-
nals a malfunction.
TRIPPED INLET CONVEYOR
INVERTER xxx
The indicated outlet conveyor motor inverter in the electrical panel

signals a malfunction.
TRIPPED OUTLET CONVEYOR IN-
VERTER xxx
The inverter of the product pump motor signals a malfunction.

TRIPPED PRODUCT PUMP Identify the inverter by referring to the wiring diagram.
INVERTER Check the indicated error code from the inverter’s user manual.
The inverter of the main motor of the filling machine signals a mal-
function.
TRIPPED FILLING MACHINE INVERT-
ER
The inverter of the air conveyor fan motor signals a malfunction.

TRIPPED AIR BLOWER INVERTER
The inverter of the sorter motor signals a malfunction.

TRIPPED SORTER INVERTER
The inverter of the capping heads motor signals a malfunction.

TRIPPED CAPPING HEADS Identify the inverter by referring to the wiring diagram.
INVERTER Check the indicated error code from the inverter’s user manual.
TRIPPED FILLER INFEED STAR-

The infeed starwheel is blocked. Remove the cause of the block and
WHEEL
phase the starwheel by turning it until it clicks.
(or RINSING MACHINE or CAPPING
MACHINE) Press RESET to restart production.
The intermediate starwheel is blocked. Remove the cause of the

TRIPPED INTERMEDIATE STAR-
block and phase the starwheel by turning it until it clicks.
WHEEL
TRIPPED FILLER OUTFEED STAR-

WHEEL The outfeed starwheel is blocked. Remove the cause of the block
(or RINSING MACHINE or CAPPING and phase the starwheel by turning it until it clicks.
MACHINE)TRIPPED FILLER OUT- Press RESET to restart production.
FEED STARWHEEL
The caps elevator motor has triggered the thermic switch inside the
electrical panel.
TRIPPED CAPS LOADER
Check operation of the caps elevator motor.

ALARMS - MESSAGES
The wash pump motor has triggered the thermic switch in the electric
WASH PUMP MOTOR THERMIC panel.
OVERLOAD Check operation of the wash pump motor.
The inlet conveyor motor has triggered the thermic switch inside the
INLET CONVEYOR electrical panel.
THERMIC OVERLOAD Check operation of the inlet conveyor motor.
The motor to adjust the height of the filling head has triggered the
thermic switch inside the electric panel.
FILLING MACHINE HEIGHT ADJUST-
Verify that nothing blocks ascent and descent of the head. Close
MENT THERMIC OVERLOAD
safety protections.
The motor to adjust the height of the capping machine head has trig-
gered the thermic switch inside the electric panel.
CAPPING MACHINE HEIGHT AD-
Verify that nothing blocks ascent and descent of the head. Close
JUSTMENT THERMIC OVERLOAD
safety protections.
The main motor of the capping machine has triggered the thermic
CAPPING MACHINE THERMIC OVER- switch inside the electrical panel.
LOAD Check the motor's operation.
The smoke suction fan motor has triggered the thermic switch inside
SMOKE SUCTION FAN the electrical panel.
THERMIC OVERLOAD Verify that nothing blocks normal operation of the fan.
The suction fan motor under the machine’s base has triggered the
SUCTION FAN UNDER BASE thermic switch inside the electrical panel.
THERMIC OVERLOAD Verify that nothing blocks normal operation of the fan.
The caps canal fan motor has triggered the thermic switch inside the
electrical panel.
CAPS FAN THERMIC OVERLOAD
Verify that nothing blocks normal operation of the fan.
The lower limit was reached during manual adjustment of the height
RINSING MACHINE AT MINIMUM LIM-
from the Touch Screen.
IT
Increase the height of the rinsing machine tower.
The upper limit was reached during manual adjustment of the height
RINSING MACHINE AT MAXIMUM
from the Touch Screen.
LIMIT
Decrease the height of the rinsing machine tower.
FILLING MACHINE INFEED GRIP- The filling machine infeed starwheel does not grip the bottles from
PERS the inlet conveyor or does not release the filling tower grippers.
SAFETY Check operation of the grippers.
RINSING MACHINE INFEED GRIP- The rinsing machine infeed starwheel does not grip the bottles from
PERS the inlet conveyor or does not release the rinsing machine tower grip-
SAFETY pers. Check operation of the grippers.
FILLING MACHINE OUTFEED GRIP- The filling machine outfeed starwheel does not grip the bottles from
PER the filling tower or does not release them on the conveyor belt. Check
SAFETY operation of the grippers.
Cap blocked in the sorter. Remove the jam.

BLOCKED SORTER

ALARMS - MESSAGES
A container is blocked near the mobile side.

TRIPPED MOBILE SIDE Remove the jam.
The capping machine is not in phase with the filling machine (pres-
CAPPING MACHINE NOT IN POSI-
ence of electric axle). Check the encoder belt and hook sensor.
TION
The sorter’s motor has triggered the thermic switch inside the electri-
cal panel.
CAPPING MACHINE SORTER THER-
Check operation of the motor and for any clogging that cause exces-
MIC OVERLOAD
sive stress on the motor.
The caps elevator motor has triggered the thermic switch inside the
electrical panel.
CAPPING MACHINE LOADER THER-
MIC OVERLOAD
The capping heads motor has triggered the thermic switch inside the
CAPPING HEADS MOTOR THERMIC electrical panel.
OVERLOAD Check the motor's operation.
The vacuum pump motor has triggered the thermic switch inside the
electrical panel.
VACUUM PUMP THERMIC OVER-
LOAD
The delivery pump motor between the burette and rinsing machine
has triggered the thermic switch in the electric panel.
RINSING MACHINE PUMP DELIVERY
THERMIC OVERLOAD
The motor to adjust the height of the rinsing machine has triggered
the thermic switch inside the electric panel.
RINSING MACHINE HEIGHT ADJUST-
MENT THERMIC OVERLOAD
The motor to adjust the height of the capping machine has triggered
the thermic switch inside the electric panel.
CAPPING MACHINE HEIGHT AD-
JUSTMENT THERMIC OVERLOAD
The motor to adjust the height of the trigger has triggered the thermic
switch inside the electric panel.
TRIGGER HEIGHT ADJUSTMENT
THERMIC OVERLOAD
The servo fan motor of the main motor has triggered the thermic
switch inside the electrical panel.
MAIN MOTOR SERVO FAN
THERMIC OVERLOAD
The servo fan motor of the product pump has triggered the thermic
switch inside the electrical panel.
PRODUCT PUMP SERVO FAN THER-
MIC OVERLOAD

ALARMS - MESSAGES
The machine’s guards are open.

Check the open guards from the CONTROL PANEL screen on the
TOO MANY OPEN GUARDS
touch screen and close them.
The sensor signals that there are insufficient caps on the release
TOO MANY CONSECUTIVE CAPS head. Some caps may be blocked on the conveyor or the sorter may
MISSING be damaged.
The indicated solenoid valve does not respond correctly to opening/

STERILE AIR ENABLING VALVE
closing commands.
OUT OF POSITION

FLAT WATER VALVE
closing commands.
OUT OF POSITION

VACUUM SUCTION PUMP VALVE
closing commands.
OUT OF POS

CO2 LOADING VALVE
closing commands.
OUT OF POSITION
CONNECTION VALVE BETWEEN THE The indicated solenoid valve does not respond correctly to opening/
PRODUCT AND CIP OUT OF POSI- closing commands.
TION Check correct operation.

VACUUM EXCLUSION VALVE OUT OF
closing commands.
POSITION

BURST BOTTLE WASHING VALVE
closing commands.
OUT OF POSITION

BURETTE WASHING VALVE OUT OF
closing commands.
POSITION

CO2 PIPE WASHING VALVE OUT OF
closing commands.
POSITION

CIP-RETURN VALVE TO CLIENT OUT
closing commands.
OF POSITION

BURETTE DISCHARGE VALVE OUT
closing commands.
OF POSITION

PRODUCT DELIVERY DISCHARGE
closing commands.
VALVE OUT OF POSITION

PRODUCT INFEED SAFETY VALVE
closing commands.
OUT OF POSITION
The wash tub is not in its usual position. This could be an obstacle
TUB OUT OF POSITION during production; proceed with repositioning the wash tub.

ALARMS - MESSAGES

PRODUCT DISCHARGE TUB OUT OF
closing commands.
POSITION
The filling valves are unable to fill the containers completely due to
EXCESSIVE SPEED the excessive production speed set.
Decrease the production speed.

ALARMS - MESSAGES
4.6 ALARM MESSAGES OF THE LABELLING MACHINE AND

RELATIVE SOLUTIONS
ALARM DESCRIPTION SOLUTION

PRE-ALARM • Pre-alarm for imminent lack of la-
ADHESIVE GROUP x bels in the reel regarding the indicat-
LABELLING MACHINE ed group.
• Check the error code displayed on the

control panel of the indicated adhesive
ALARM
• The indicated adhesive labelling group.
ADHESIVE GROUP x
LABELLING MACHINE
station signals a malfunction. • Check the adhesive station manual.
• Reset the error on the display of the adhe-
sive group and on the touch screen.
JOG EMERGENCY
• Error due to pressing the emergen- • Extract the emergency push button.
LABELLING MACHINE
PRESSED
cy push button on jog. • Reset the error on the touch screen.
FRONT EMERGENCY • Error due to pressing the emergen-

• Extract the emergency push button.
LABELLING MACHINE cy push button on the front part of the
PRESSED
• Reset the error on the touch screen.
labelling machine.
BACK EMERGENCY Error due to pressing the emergency

• Extract the emergency push button.
LABELLING MACHINE push button on back labelling ma-
PRESSED
chine.
TRIPPED LH • There are blocked containers in line • Remove the jam.

LABELLING MACHINE with the left infeed worm screw of the • Phase the worm screw
INFEED WORM labelling machine. • Reset the error on the touch screen.
TRIPPED RH • There are blocked containers in line • Remove the jam.

LABELLING MACHINE with the right infeed worm screw of • Phase the worm screw
INFEED WORM the labelling machine. • Reset the error on the touch screen.
TRIPPED • Release the infeed starwheel.

• The infeed starwheel of the labelling
LABELLING MACHINE • Phase the starwheel.
INFEED STARWHEEL
machine is blocked
TRIPPED
• Release the outfeed starwheel.
LABELLING MACHINE • The outfeed starwheel of the label-
• Phase the starwheel.
OUTFEED STAR- ling machine is blocked
WHEEL • Reset the error on the touch screen.
• Check the air treatment group (the pres-

NO AIR
sure can be seen from the pressure gauge)
GENERALE [GENER- • There is insufficient air incoming
and reach the pressure indicated in the ma-
AL] into the labelling machine.
LABELLING MACHINE chine’s user manual.

ALARMS - MESSAGES

PRODUCTION
PRODUCTION
By pressing the indicated icon, you access the PRODUCTION page. From this page you
can perform tasks related to the machine production cycle and view the status of the pro-
duction in progress. Press the buttons to enable or disable the various functions. When the
function is enabled, the push button becomes green.
The values modified in the PRODUCTION menu are changed to the recipe be-
ing used and transferred directly to the plc of the machine in real time.
It is not a temporary change. The new values will apply when the recipe that
has been changed is used again in the future.

PRODUCTION
RINSING MACHINE
FILLING MACHINE
CAPPING MACHINE
LAMINAR FLOWS
This page displays all production data. The total number of bottles filled, the bottles filled cor-
rectly, the number of bottles rejected (the total of each reject indicates the number of total
rejects), the product level in progress and the virtual level (actual and programmed). It is also
possible to enable and disable product infeed into the tank (if you want to empty it) and the
virtual level (if already enabled based on the format).
Press in the indicated field to access the page where it is possible to change
PRODUCT FEEDING PUMP
TANK LEVEL
TANK PRESSURE

PRODUCTION
CAPS HOOK
CAPS ELIMINATED
5.1 SETUP
ELECTRONIC RINSING MACHINE SETUP

PRODUCTION
PRODUCT PUMP AND LEVEL SET-UP
CAPPING MACHINES SET-UP

PRODUCTION

PRODUCTION
5.2 VALVES LAYOUT
The operating status of the product valves are displayed in real time (open, closed, opening
percentage, etc.).

PRODUCTION
5.3 MANUAL CONTROLS
This page enables you to run manual tests. It is possible to manually edit certain machine
settings.
RINSING MACHINE

PRODUCTION
CROWNCAPPING MACHINE
ALUMINIUM SCREWCAPPING MACHINE

PRODUCTION
5.4 P.I.D.
The maintenance technician can edit the tank’s pressure and level from this page.

PRODUCTION
5.5 ELECTRIC AXLES
This screen displays the status of the electric hook between the rinsing machine and filling
machine, and between the filling machine and capping machine.

PRODUCTION

PRODUCTION

PRODUCTION
5.6 SELECTING THE PROGRAM
Press the push button to access the page where to enable or disable the pre-set work and
wash programs.

PRODUCTION

CONTROL PANEL
CONTROL PANEL
By pressing the circled icon, you can access the CONTROL PANEL page. From this page
you can perform operations related to the machine general controls.

CONTROL PANEL
6.1 TANK HEIGHT ADJUSTMENT
6.2 CAM REGULATION

CONTROL PANEL
6.3 RINSING MACHINE REGULATION
6.4 CAPPING MACHINE HEIGHT ADJUSTMENT

CONTROL PANEL
6.5 LIST
6.6 EXTERNAL DEVICES

CONTROL PANEL
6.7 ACCESSORIES
6.8 EXTERNAL WASHES

CONTROL PANEL

DIAGNOSTICS
DIAGNOSTICS
By pressing the indicated icon, you can access the DIAGNOSTICS page. From this page, it
is possible to run a check-up in real time of the various functional parts of the machine. Be-
sides working automatically, the machine can also work manually;
some operations require the supervision of the operator and the manual movement of some
machine parts.
7.1 EXCHANGE SIGNALS

DIAGNOSTICS

SERVICE
SERVICE
MACHINE INFORMATION
The screen displays the technical data of the machine.
SOFTWARE INFORMATION
The screen displays the data of the panel in use of the installed programs and of the plc in
use.

SERVICE
8.1 SERVICE - SYSTEM LOGS
This page displays the chronology of system logs.

SERVICE
8.2 SERVICE - BACKUP / RESTORE
The screen allows panel data to be imported or exported from or onto an external storage
device.
BACKUP / RESTORE USB
The entire project is exported by performing a backup on a USB key.

By importing, instead, the entire project, which must be located in the root directory of the
USB key, is imported.

SERVICE

The User may enter their own data to be used as a reminder for proper scheduled mainte-
nance.
Regular cleaning and maintenance of machines give good working results.
Certain faults and repairs may be prevented with careful cleaning and maintenance. There-
fore, regularly perform all cleaning and maintenance operations!
The screen lets you enter a list of maintenance operations to be performed at predefined
time intervals.
Upon reaching these intervals, the MAINTENANCE signal appears in the lower bar of the
Touch Screen.


SETUP MIXER
SETUP MIXER
10.1 MIXER SETTINGS
Below is the list of the buttons to use for mixer management together with their relative func-
tion:
Push this botton to start the CIP cycle
Push this botton to stop the CIP cycle
Push this botton to reset the CIP settings
Indicate the CIP cycle is running
Indicate the CIP cycle is finished

SETUP MIXER
SELECT PRODUCT TO BE USED
All you need to do is select the desired recipe in the PRODUCTS main screen, then press
the CYCLE START to activate it.
You can select one of it or both.
ATTENTION! The selected recipe cannot be loaded if the machine is moving

(stop the machine and load).

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CONTENT

1.1 TOUCH SCREEN 1

4.1 ALARM HISTORY 22

Instruction manual - Content - 1

6.1 TANK HEIGHT ADJUSTMENT 54

7.1 EXCHANGE SIGNALS 59

8.1 SERVICE - SYSTEM LOGS 62

10.1 MIXER SETTINGS 67

2 - Content - Instruction manual

TOUCH SCREEN INSTRUCTIONS

1.1 TOUCH SCREEN

1.2 LIST OF CONTROLS

MACHINE RUNNING (White)

Operator Manual - Chapter 1 - 1

MACHINE STOP (Black)

RESET - EMERGENCY (Blue)

CONTAINERS ENTRANCE ENABLING

Transponder read / write RFID unit

The machine is equipped with a mobile-jog push-button panel on which

2 - Chapter 1 - Operator Manual

Purpose of this document:

Operator Manual - Chapter 1 - 3

1.4 SAFETY STANDARDS/WARNINGS

While the machine is running, comply with:

• The following is a list of buttons displayed on the Touch screen pages.

ATTENTION: Incorrect touch screen use

ATTENTION: Unauthorised access to higher levels

• Always perform login before starting to work on the touch screen.

4 - Chapter 1 - Operator Manual

1.5 TOUCH SCREEN BROWSING

TOP STATUS BAR

Operator Manual - Chapter 1 - 5

1.6 MENU BAR

ALARMS AND MESSAGES

6 - Chapter 1 - Operator Manual

CONTAINERS ENTRANCE ENABLING

OPEN/CLOSE SAFE GUARDS

DOUBLE TOUCH ENABLING BUTTON ON THE

Operator Manual - Chapter 1 - 7

1.7 TOP STATUS BAR

8 - Chapter 1 - Operator Manual

1.8 PANEL LOGIN

To LOGIN in the control system, it is not necessary to have a

The user levels already set on the panel are:

ATTENTION: Access level abuse

Operator Manual - Chapter 1 - 9

1.10 EXAMPLE OF VALUE MODIFICATION

To modify the selected parameter, just enter the new

10 - Chapter 1 - Operator Manual

1. Sensor Level Regulation;

Operator Manual - Chapter 2 - 11

3. Sensor Height Regulation;

4. Start/Stop Machine Sensors Settings

12 - Chapter 2 - Operator Manual

5. Settings - Filler Washing Programs;

6. Settings - Filler Washing Programs;

Operator Manual - Chapter 2 - 13

14 - Chapter 2 - Operator Manual

ATTENTION! It is not possible to transfer the selected format during produc-

Operator Manual - Chapter 3 - 15

Create a new recipe

Permanently eliminates a recipe from the drop-down list