MANUAL

ASP PACKER
274-272

ATD MACHINERY B.V.

Smaragdweg 30
5527 LB HAPERT
The Netherlands
0031 (0)497 786 500

Website: www.atdmachinery.nl
General: info@atdmachinery.nl
Service: service@atdmachinery.nl

716565482.docx
 FOREWORD

This user manual relates to the machine. The information provided is important for
the proper and safe functioning of the machine.
If you are not familiar with the operation, preventive maintenance, etc. of the
machine, you should study this user manual carefully. If you are familiar with the
machine, this user manual can serve as a reference book. To quickly and easily find
the necessary information, you can use the table of contents.

If the instructions in this manual are not followed, the warranty of ATD Machinery is
void. The conditions in which the machines are installed, operated, used and
maintained, as well as the methods used, are beyond ATD's control. ATD Machinery
is therefore not liable for damage or loss as a result of improper use or incorrect
installation, operation, use or maintenance.

In this document, the machine is also referred to by the words system or machine.
Function keys are enclosed in rectangular brackets, for example, [START]. If you
have any questions, you can always contact ATD Machinery.
To emphasize different topics or actions, the following marking conventions have
been used in this guide.

Tip! Give you suggestions or advice to make an action easier.

Pay attention ! Be aware of possible problems.

The installation may be damaged if you do not perform the described

Cautious!
procedures carefully.

You can (seriously) injure yourself or the installation can suffer serious
Warning!
damage if you do not carry out the described procedures carefully.

Procedures that must be performed in a specific order are displayed in the following
way:
1) Procedure 1
2) Procedure 2

Etc.

Foreword
Manual .ASP

© Copyright 2011
All rights reserved. No part of this publication may be reproduced, stored in a
retrieval, or made public in any form or by any means, electronic, mechanical,
photocopying, recording, or by any means without the prior written permission of ATD
Machinery. This also applies to the corresponding drawings and diagrams.
ATD Machinery reserves the right to change parts at any time, without prior or direct
notice to the customer. The contents of this user manual are also subject to change
without prior warning.
For information regarding installation, maintenance work or repairs not provided for in
this user manual, please contact the technical service of the supplier.
This user manual has been compiled with all possible care, but ATD Machinery
cannot take responsibility for any errors in this user manual and/or for the
consequences thereof.

Foreword
Manual .ASP

TABLE OF CONTENTS
1 Machine-/installatieinformatie................................................................................3
1.1 Company information.....................................................................................3
1.2 Production/plant data.....................................................................................3
1.3 Procesbeschrijving.........................................................................................3
1.3.1 General...................................................................................................4
2 Safety....................................................................................................................5
2.1 Machinegebruik..............................................................................................5
2.2 Intended use..................................................................................................6
2.3 Target audience.............................................................................................6
3 Transport and installation of the machine(s).........................................................7
3.1 Transport and installation...............................................................................7
3.2 Connect..........................................................................................................7
4 Use of the machine(s) and the entire installation..................................................8
4.1 General..........................................................................................................8
4.1.1 Mass-flow................................................................................................9
4.1.2 Empty boxes supply..............................................................................10
4.1.3 Slat magazine + puncture unit + number of checks.............................11
4.1.4 Vacuümband.........................................................................................12
4.1.5 Papierunit..............................................................................................14
4.1.6 Bakjesband...........................................................................................16
4.2 Controls........................................................................................................17
4.2.1 Noodstopdrukkers.................................................................................17
4.2.2 Control panel........................................................................................17
4.2.3 [EMERGENCY STOP] Red mushroom bud.........................................17
4.2.4 [START] push button with green signal light.........................................18
4.2.5 [STOP] push button with red signal light...............................................18
4.2.6 Selector switch [AUTO HAND].............................................................18
4.2.7 Switch [Porridge. Unit]..........................................................................18
4.2.8 Switch [ /0/ ]......................................................................................18
4.3 Control cabinet.............................................................................................19
4.3.1 Main switch...........................................................................................19
4.3.2 Tornsnoer [SERVICE]...........................................................................19
5 Service................................................................................................................20
5.1 Inspections...................................................................................................20
5.2 Boot..............................................................................................................20
5.3 Operation during production........................................................................20
5.4 Decommissioning.........................................................................................20
6 Convert to another product.................................................................................22
6.1 Mass-flow.....................................................................................................23
6.2 Slat magazine..............................................................................................24
6.3 Number of checks........................................................................................24
6.4 Prikunit.........................................................................................................25
6.5 Bakjesband..................................................................................................25
6.6 Funnel..........................................................................................................26
6.7 Papierunit + papierklem...............................................................................27
6.8 Empty boxes warehouse..............................................................................28
6.9 Boxes clamp and boxes opener...................................................................29
6.10 Cigar pusher................................................................................................30
Back guide, paper folder and boxes shutter...........................................................31
6.11 Stacker and full box warehouse...................................................................32
7 Adjustments and adjustments, malfunctions and maintenance..........................33
7.1 Operator panel.............................................................................................33
7.1.1 Keys/information displayed on the main screen...................................33

Table of contents
Manual .ASP

7.1.1.1 Menutoetsen ...................................................33

7.1.1.2 Function keys ...................................................34

7.1.1.3 Pop-up menu knop ................................................................34

7.1.1.4 Information.....................................................................................35
7.1.2 Menu [Productiegegevens] ...........................................................36
7.1.3 [Settings] menu ............................................................................37
7.1.3.1 Submenu [Ridge Settings] ....................................................38
7.1.3.2 Submenu [Other] ...................................................................39
7.1.4 Menu [Service] .............................................................................40
7.1.4.1 Submenu [Status INPUTS/OUTPUTS] .................................41
7.1.4.2 Submenu [Force Outputs] ....................................................42
7.1.4.3 Submenu [Netwerklayout] .....................................................43
7.1.4.4 Submenu [Servo] ..................................................................43
7.1.4.5 Test production .....................................................................45
7.1.4.6 Version information........................................................................45
7.1.4.7 Change password..........................................................................46
7.1.4.8 Runtime termination......................................................................46
7.1.4.9 Adjust date/time.............................................................................46
7.1.4.10 Product register.............................................................................46
7.2 Alarmanalyse...............................................................................................48
7.3 Malfunctions not displayed by the installation..............................................54
8 Belong.................................................................................................................55
8.1 Pneumatic diagram......................................................................................55
8.2 Spare Parts List...........................................................................................55
8.3 Formaatdelenlijst..........................................................................................55
8.4 Smeerschema..............................................................................................55
9 Keyword list, icons, attachments.........................................................................56
9.1 Glossary.......................................................................................................56
9.2 Icons............................................................................................................56
9.3 Attachment...................................................................................................56

Table of contents
Manual .ASP

1 MACHINE-/INSTALLATIEINFORMATIE

1.1 COMPANY INFORMATION

ATD Machinery
Smaragdweg 30
5527 LB HAPERT
Netherlands

Tel.: +31 (0)497 786 500

Fax: +31 (0)497 786 550

1.2 PRODUCTION/PLANT DATA

Mass : 2300 and 790 kg
Capacity : Max. 60 boxes per minute
Electrical power supply : See identification plate on
control cabinet
Required pressure : Min 6 bar

Noise level
The noise level has been measured according to the requirements of the Machinery
Directive. The A-weighted sound pressure is measured at the workplace during
normal working conditions. The measurement was carried out at a distance of 1
meter from the machine surface and at a height of 1.60 meters above the ground.
The level of the A-weighted equivalent continuous sound pressure (Laeq) is below 70
dB(A) .

1.3 PROCESS DESCRIPTION

The ASP, is a standalone machine and can be part of an automatic production line
for packing cigars. The operator is responsible for starting up the machine, filling the
cigar warehouse, the warehouse for the boxes, picking up boxes, monitoring the
production process and intervening in case of problems (error messages) during the
production process.

Machine-/installatieinformatie 3
Manual .ASP

1.3.1 GENERAL
The ASP, ATD Shoulderbox Packer has been developed to pack cigars. The
cigars are supplied by the mass-flow (1). The mass-flow contains a magazine from
which the cigars are fed. At the end of the mass flow there is a full and empty
notification. Under the mass-flow are slats magazines. Here the cigars are separated
into channels. Under the slat warehouse, 1 row of 5.8 or 10 cigars is slid each time.
These cigars are perforated at the next position. Then they are slid into a container
belt. From the second slat magazine, a 2nd layer is added to the tray if the operator
enters it. From the tray, one or two layers are slid into the box. During this slide-in,
you can choose to fold paper around the package of cigars. This can be in the form
of an insert or a lover. The empty box warehouse feeds boxes on a vacuum belt.
When the machine requests it, empty boxes are bumped into the warehouse by
means of a cylinder. The bottom box in the warehouse is pulled onto a conveyor belt
by means of a ridge and vacuum. After inserting the cigars, the folded paper is
brought up in the next position. Then a folding unit folds the front flap into the box.
Then the box is closed. At this position there is also the option to apply a traceability
code (option). After this position, the boxes are stacked in the full boxes warehouse.
The rejection boxes follow the other path and are injected. The machine is equipped
with its own control box (3) with control box (2).

(1) (2) (3)

Machine-/installatieinformatie 4
Manual .ASP

2 SAFETY

2.1 MACHINE USAGE

 Operations on the machine may only be carried out if one is aware of the
contents of this user manual.

 If several people are working on the machine, good cooperation and proper
coordination of the work will be necessary.

 The operating personnel must be provided with information and instructions

about the production process and the safe operation of the machine. The
operating staff must also be aware of all possible aspects of danger and how they
should be handled.

 No changes and/or modifications may be made to the machinery without written

permission from the manufacturer.

 Inspections and maintenance should be carried out as indicated in this user

manual.

 The professional competence and sense of responsibility of the user largely

determine the safe and efficient use of the machine.

 Locally applicable labor and safety laws and regulations must always be followed.
This also applies to environmental legislation.

 If the staff identifies errors or danger or does not agree with the safety measures
taken, the owner or main responsible person must be informed immediately.

 The workplace must be sufficiently spacious and free of obstacles.

 Working on the machine has two levels of user:

- operator (level A).
- maintenance and installation (level B).
If no user level is mentioned, this means that said work can be carried out by the
operator (level A).
If level B is indicated, this means that the said work must be carried out by a
person (persons) who is (are) trained and competent for this.

 The use of a logbook is recommended if this results in better coordination

between the users of the machine.

 Decommissioning must comply with local regulations. No substances are

processed in the machine that require special care when dismantled.

 The safety aspects must be known. The safe use of the machine must be
paramount.

Safety 5
Manual .ASP

 Safety devices should never be removed while the machine is in operation. If this
is necessary for maintenance work, bridging tools can be used. The work must
be carried out by authorised personnel. Personnel should be aware of the
hazards that may occur.

 If there is any doubt about the safety measures to be taken, the supplier of the
machine should always be consulted.

 The safety devices must be checked daily for presence and correct functioning
before the use of the machinery.

 Preferably use spare parts and other parts prescribed by the supplier of the
machine.

 During production, the control cabinet of the machine must be closed.

2.2 INTENDED USE

The terms and conditions are described in this user guide. Other uses are seen as
improper use; Any resulting damage and/or injuries are not the responsibility of the
manufacturer.

2.3 TARGET AUDIENCE

The target group of this user manual consists of authorized persons and technically
competent persons.

Authorised persons are persons who:

 and have built up a certain level of knowledge through education / training;
 and have certain skills to operate the packing machine.

Technically competent persons are persons who:

 and be competent;
 and have built up a certain level of knowledge through education / training;
 and be familiar with the technology of the machine;
 and be aware of the possible dangers and risks. (personnel trained by "ATD
Machinery")

Operating the machine includes: operating the machine, cleaning the machine and
simple maintenance work.
The purpose of this user manual is to obtain a safe and efficient interaction between
man and the machine.

Safety 6
 Manual .ASP

3 TRANSPORT AND INSTALLATION OF THE MACHINE(S)

3.1 TRANSPORT AND INSTALLATION

Transport
The machine is designed in such a way that it can easily be transported with the
forklift. Place the forks under the frame so that the system cannot slip. Despite these
provisions, caution during transport is necessary.

Make sure that no electrical cables are pinched by the forks of the
Warning!
forklift.

Requirements for the environment

In general, this machine does not place any special demands on the floor space; A
flat concrete floor is sufficient. During production, the machine and its immediate
surroundings must be well lit.

3.2 CONNECT
In this section, instructions follow how to set up and install the machine:
1. Unpack the machine.
- Remove packaging material without harming the environment.
- Check if the machine is damaged.
- If any damage is detected, please contact the supplier immediately.
- Degreasing machine completely, paying special attention to format parts and other
parts that come into contact with tobacco.
2. Check the location. Place all machine parts on a flat concrete floor and adjust the
machine horizontally using the adjustable supports. Connects the machine parts
to each other.
3. Connect all machine parts with the supplied cables, see also the supplied
electrical diagrams.
4. Connect the power cable (not included). To do this, use the electrical diagram;
This is located on the inside of the control cabinet.
Once the machine is installed, all people involved in this machine must be trained
with regard to construction, supervision, functioning, maintenance, safety measures
and specifications based on this user manual.

Transport and installation of the machine(s) 7

Manual .ASP

4 USE OF THE MACHINE(S) AND THE ENTIRE INSTALLATION

4.1 GENERAL
The system is made up of different parts. The main components of the ASP are
shown in the figure below.

1 2 3

8 4 5 7 6

1 Mass-flow
2 Empty boxes supply
3 Slat magazine + puncture unit + number of checks
4 Vacuümband
5 Papierunit
6 Rejectie
7 Touch screen
8 Bakjesband

Use of the machine(s) and the entire installation 8

Manual .ASP

4.1.1 MASS-FLOW
The mass flow transports the cigars in bulk from the warehouse to the slat
warehouses. The mass flow consists of two conveyor belts, which are driven by a
motor. The mass flow fills itself until a microswitch is operated and then stops
transporting. Because the machine continues to run, the switch is released at a
certain moment and the mass flow starts running again. The mass-flow therefore
maintains the buffer.

1 3 2 7 6 4 5

1. Warehouse
2. Foreclosure
3. Sensor
4. Conveyors
5. Aandrijfmotor
6. Adjustable backplate
7. Microswitch

The rear of the mass-flow contains all the drives for the conveyor belts. In addition, at
the back is the complete construction to adjust the rear wall of the mass flow. This is
to set the length of the cigar.

Use of the machine(s) and the entire installation 9

Manual .ASP

4.1.2 EMPTY BOXES SUPPLY

The empty boxes are in the box warehouse. A sensor (1) registers when the stack of
boxes on the vacuum edge has been processed. At that moment, the cylinder (2)
slides a complete stack of boxes onto the vacuum belt. At the end of this stroke, an
extra cylinder (3) ensures that the stack also tilts over on the vacuum belt, which is at
an angle of 10 degrees. After this stack has been moved, the motor (4) continues
the conveyor belt. As a result, a new stack is ready to be transferred to the vacuum
belt.
With the help of a number of transporters on the vacuum rim, the bottom box of the
stack is taken each time. The box is clamped to the vacuum belt by vacuum. The
vacuum is created with an integrated pump.

1 2 3 4

Use of the machine(s) and the entire installation 10

Manual .ASP

4.1.3 SLAT MAGAZINE + PUNCTURE UNIT + NUMBER OF CHECKS

The cigars that are supplied from the mass flow end up in a slat warehouse. This
magazine is adjustable in length and forms one layer of cigars. The pusher extends 1
layer below the rest each time. The number of channels used determines the number
of cigars in one layer. At the top of the warehouse, tilting shafts are provided to
ensure the flow of cigars.

Use of the machine(s) and the entire installation 11

 Manual .ASP

The cigars are extended and slowly compacted in the flow. At the next position, the
cigars are ready to be perforated. This pricking is done to promote the craving for a
cigar.

The puncture unit is curve controlled. In order to be able to prick from 1 side, a
system has been built in that can be switched on or off so that the do or do not
participate. If you do not want to prick from below, an insert will have to be inserted in
the format part. The top puncture bar can be adjusted in height and can be removed
quickly in the event of a malfunction.

4.1.4 VACUUM BELT

The boxes that are taken from the empty box warehouse end up on a vacuum belt.
There is a clamping position on the vacuum rim. At the clamping position, the box is
clamped by a lever mechanism. An arm that makes a rotating motion opens the box
(1).

At a next position, the package of cigars is slid into the box, after which the package
is pressed into the box by a pusher. This pusher (2) is also the top guide for the
paper during the passage of the box.

Make sure that there is no empty position on the "vacuum belt". This can
Note!!
cause problems for holding the boxes.

Use of the machine(s) and the entire installation 12

Manual .ASP

A few positions further, the paper is folded into the box (3), then the lid of the box is
closed (4) and the box is pressed shut (5).

The central vacuum pump ensures sufficient vacuum in the conveyor belt. Hoses
provide each part of the vacuum edge with sufficient vacuum. To reduce the noise
level, the pump is equipped with a silencer.

Use of the machine(s) and the entire installation 13

Manual .ASP

4.1.5 PAPIERUNIT
The paper insert consists of a reel with paper roll, a number of feed rollers, a brake, a
clamp and a cutting mechanism.
The feed rollers transport the paper to the filling unit where it is clamped at the end
and cut off on the other side. At the same time as the cigars are inserted, the paper is
placed in the ready box and folded over. When the cigar pusher is activated, the
clamping mechanism(1) is relieved so that the paper is only slightly held by a spring
mounted on the pusher. The cylinder (2), which is mounted on the tie rod, also allows
slip to be fed. In this way, paper can be taken from above and from below.
By adjusting the height of the paper insert with the motor (3) adjustment, the cutting
length of the paper is determined. The desired overlap of the paper ends must be
taken into account. The sensor (4) on the paper unit determines the position of the
paper.

3 4 1 2 4

Use of the machine(s) and the entire installation 14

Manual .ASP

The paper transport is carried out with dancer rollers. This is to prevent the paper
from tearing or becoming loose during the acceleration and slowing down of the
paper roll.

On the paper head there is a control panel (4) with 3 buttons: continue, cut and
hand/auto.
Continue: The paper roll is continued for 1 cycle, either until a subsequent
printing mark or a fixed distance.
Cut: By pressing on this, the paper is cut off
Hand/car: Because the system is connected to a servo, it must be temporarily
"disconnected" so that the roll can be continued by hand for entering
the paper, so set this button to HAND. To then run the paper head in
normal operation, set it back to AUTO.

Use of the machine(s) and the entire installation 15

Manual .ASP

4.1.6 BAKING TAPE

The tray belt transports the cigars from the slat warehouse to the slide-in position in
the box. This entire band is adjustable in height (1). This is because the boxes all
have different heights. The trays pass the two slat magazines where a layer of cigars
may or may not be slid into the tray. In this way, a double layer cigar package can be
formed.

1
At the end of the belt is the slide-in position where the pusher (2) slides the cigars
into the box. A funnel (3) holds the package together.
2

Use of the machine(s) and the entire installation 16

Manual .ASP

4.2 CONTROLS

4.2.1 EMERGENCY STOP PRESSURES

The machine is equipped with a number of emergency stop pressers. Operating one
of these emergency stop pushbuttons switches off the main flow and compressed air
of the machine. In other words, the machine is energyless. To unlock the emergency
stop push button, it must be turned a quarter turn to the left. Only when all push
buttons are unlocked, the machine can be restarted.

4.2.2 CONTROL PANEL

The control panel is used to adjust the settings of the machine and to read production
data and the status of the machine. The malfunctions and alarms are also displayed.
The layout of the control panel is shown below.

In addition, a pressure set is mounted on the machine.

4.2.3 [EMERGENCY STOP] RED MUSHROOM BUTTON

The machine is equipped with an emergency stop pusher, which is located on the
pressure set. Operating an emergency stop push button switches off the main flow
and compressed air of the machine. In other words, the machine is energyless. To
unlock the emergency stop push button, it must be turned a quarter turn to the right.
Only when the push button is unlocked can the machine be restarted.

Use of the machine(s) and the entire installation 17

 Manual .ASP

4.2.4 [START] PUSH BUTTON WITH GREEN SIGNAL LIGHT

The [START] button is used to start the machine and to reset alarms. In case the
machine is not yet booted, the [START] button flashes. By pressing the [START]
button, the emergency stop relay switches on, provided that all emergency stop
pushers are unlocked. The [STOP] button is illuminated in red and after 3 seconds
the [START] button will flash again.
By pressing [START] now, the machine becomes ready for use. Depending on the
selector switch [AUTO HAND], production is started or the machine can be operated
manually. In this situation, the [START] signal lamp is lit.

4.2.5 [STOP] PUSH BUTTON WITH RED SIGNAL LIGHT

The [STOP] button is used to stop the machine. When the machine is stopped, the
[STOP] button is illuminated in red. By holding down the [STOP] button for 2
seconds, the auxiliary drives such as the vacuum pump also stop.

The stop state is a non-safe state. It is therefore not permitted to carry

Warning!
out work in the machine in the stop state.

4.2.6 SELECTOR SWITCH [AUTO HAND]

Using the selector switch [AUTO HAND] you can switch between automatic
production running or manual production at lower speed.
Manual production is only performed during the time that the [START] button is also
pressed.

In Hand mode, a number of door guards have been bridged. The

Warning! operator must always convince himself that there are no other people
working in the machine.

4.2.7 SWITCH [PORRIDGE. UNIT]

With the help of this switch, the paper unit can be sent up or down.

4.2.8 SWITCH [/ 0/ ]
If the switch is in the [0] position, nothing happens. If the doors are closed and the
switch is turned to the [ ] symbol, the paper roll 1 cycle will be continued, either until
a subsequent printing mark or a fixed distance. If the doors are closed and the switch
is turned to the [ ] symbol, the paper is cut off.

Use of the machine(s) and the entire installation 18

 Manual .ASP

4.3 CONTROL CABINET

The following sections clarify the function of these components.

4.3.1 MAIN SWITCH

The main switch switches off the machine completely. In the off position, the main
switch can be locked with a padlock.

If maintenance is carried out on the machine, the main switch must be

Warning! switched off and the service technician must lock the main switch with
his personal padlock.

4.3.2 TORNSNOER [SERVICE]

The machine is equipped with special controls for the service technician. To do this,
the torn cord must be inserted into the connector. It is now possible to operate the
machine by pressing the push button on the torn cord. This function may only be
performed by an instructed service technician, who is responsible for the safe
operation of the machine.

Use of the machine(s) and the entire installation 19

Manual .ASP

5 SERVICE

5.1 INSPECTIONS
The ASP is equipped with a shield to protect the operator. The transparent shielding
enables the operator to continuously monitor the production process. Within the
shield is a zone, in the vicinity of moving parts, where there is a risk of clamping. It is
also possible to open the guard, for example for adjusting folding guides. All doors on
the top are equipped with safety switches that stop the machine immediately when a
door is opened. The front is equipped with a light curtain. Before the machine can be
used for production, the following points must be checked:

 No loose connections and/or damage to the machine

 No obstacles in the machine (such as leftover tools, etc.)
 Compressed air tap opened (operating pressure 6 bar)
 Main switch enabled
 Presence and functioning of safety devices
 Alle noodstopdrukkers ontgrendeld
 All doors and fixed guards closed and in place
 Box available in warehouse
 Cigars present in mass-flow
 Paper present on paper unit

5.2 BOOT
After the inspections of the previous paragraph have been carried out, the machine
can be started.
 Press [START] on the control panel; The emergency stop relay is switched on.
 Press [START] again when the button flashes; The machine transitions into
automatic operation.

5.3 OPERATION DURING PRODUCTION

 General machine checks, such as weird noises and leaks.
 Refill boxes.
 Refill cigars.
 Refill paper.

5.4 DECOMMISSIONING
 Perform any empty procedure.
When changing cigars, one can first empty the mass flow by pressing the

button . It turns red to indicate that it no longer checks for drain

When the mass flow is empty, the buffer can be emptied by pressing the button

. It also turns red to indicate that it no longer checks for depopulation.

Finally, the machine can be emptied by pressing the button .

Service 20
Manual .ASP

 Turn off the main switch.

 Close the compressed air tap.

Service 21
Manual .ASP

6 CONVERT TO ANOTHER PRODUCT

The machine is adjustable to other products. The following parts must be swapped:

2 1 3 4 5 6 10 7 8 9 11

1. Slat magazine (2x) (when diameter range changes)

2. Number of control (2x) (when diameter range changes)

3. Emitter slat magazine (2x)

4. Size plate compaction (2x)

5. Compact go-getter (4x)

6. Trays of baking tape (16x)

7. Inpusher

8. Top plate funnel

9. Cigar pusher

10. Clipping plate box opener (when changing can-cardboard-plastic)

11. Pusher stacker

Convert to another product 22

Manual .ASP

12. If necessary, adjust the number control to the desired number of channels in the
warehouse.

13. If necessary, also adjust the zero point of the box tape so that the zero line is
equal (see later description)

6.1 MASS-FLOW
Adjusting the mass flow to the length of the cigar is done by adjusting the back wall
(1). At the front of the mass-flow there is a handwheel (2) that can be twisted. This
handwheel is connected to the back of the mass-flow where there is a mechanism (3)
that allows the rear wall to move over straight guidance.

1 2 3

The output side of the mass-flow is located above the slatted magazines. In order to
feed the cigars precisely into the warehouses, guide plates have been fitted to the
magazines. With the help of these plates, the number of channels used can also be
determined. The cigars can be sent into the right channels.

Convert to another product 23

Manual .ASP

6.2 SLAT MAGAZINE

The slat magazine is designed to handle a certain diameter range of cigars. When
the cigars fall into the range, it is possible to set the length and number of cigars on
the machine. The number of cigars can be determined in the mass-flow as described
above. The length of the cigar can be determined by means of the handwheel (1) at
the warehouse. The clock (2) mounted after the handwheel indicates the length that
the magazine can process. The strip (3) that is mounted at the bottom of the
magazine can still be adjusted to get a nice passage for the cigars so that no second
cigar can be extended.

3 1 2

6.3 NUMBER OF CHECKS

The unit for number of control that is built up on the machine is exchanged per
diameter range. The pitch of the sensors depends on the pitch of the channels in the
slat magazine. However, when cigars are processed in the same diameter range, this
unit does not need to be exchanged. However, the height must then be adjusted.
Because the beam with sensors runs over a wedge by means of shape assurance, it
is easy to adjust in height. For this, one only needs to remove the swivel arm (1) and
adjust the height of the beam.

Convert to another product 24

Manual .ASP

6.4 PRIKUNIT
The puncture unit perforates the cigars above or below and above if desired. In
addition, by completely removing the top pin bar (1), you can also choose not to prick
at all. By turning the adjustment knob (2), the top time bar can be adjusted in height.
This adjustment is necessary to compensate for the difference in cigar diameter.
When only pricking is required from above, the cylinders (3) enter the lower puncture
bar (4). The skewers still move vertically according to the curve path, but no longer
exceed the 0 level. In order not to get a large transition, an inlay plate must be placed
in the format part for compacting.

6.5 BAKJESBAND
The tray belt contains holders where the size parts, the trays, can be set up. In
addition to this format change, a number of things have to be adjusted to be able to
run with a different format. Firstly, the height of the bucket belt must be adjusted by
means of a handwheel (1). This height should be such that the cigar goes over the
edge of the box during the bump. A higher box means a higher setting. In addition to
this height adjustment, the top guide (2) must also be adjusted to the diameter of the
cigar. And finally, the final stop (3), which is determined by the cigar length, must be
adjusted to the correct size.

2 1 3 height tray belt height box

Convert to another product 25

Manual .ASP

6.6 FUNNEL
When the cigars are slid out of the container belt into the box, they pass through a
funnel. This funnel forms a nice package of cigars, single or double layer. The upper
guide (1) is a format part. This determines the height and width of the cigar package.
The rest of the funnel is adjusted by moving the right side of the funnel (2). This can
be done by unscrewing the screw nuts (3) and sliding them upside. The left side of
the funnel is the 0-line and always remains.

1 2 3

Convert to another product 26

Manual .ASP

6.7 PAPIERUNIT + PAPIERKLEM

The paper unit is adjustable to determine the paper length. By adjusting the height
using the linear motor (1), the distance of the cutting knife (2) and the paper clip (3)
becomes different. This distance is the paper length. At the bottom of the paper unit
there is a sensor (4) which determines the position of the paper. This sensor looks at
a mark on the paper and the servo then knows when to stop turning in order to lay
the paper down properly.

3 2 1 4

The paper clamp is needed to hold the paper while sliding in the cigar package.
When the package is pushed in far enough, the clamp opens and the paper will also
be taken from the bottom. This construction is equipped with a cylinder (5). With the
help of this cylinder it is possible to take paper from below for certain sizes of boxes.
By sending out the cylinder, the spring pressure (6) of clamping decreases and slip
will occur between the clamp and the paper. In this way, regardless of the curve path,
it is possible to take paper from below earlier.

5 6

Convert to another product 27

Manual .ASP

6.8 EMPTY BOXES WAREHOUSE

The empty box magazine is completely adjustable and contains no size parts. The
fixed wall (1) on the front is the 0-line and therefore not adjustable. This also applies
to the left wall (2). The wall at the rear (3) can be completely adjusted to straight
guidance. This can be done by loosening the clamping levers (4) and shifting the
wall. In this way, the length of the box is adjusted. The width direction of the box is
adjusted by detaching and sliding the side wall (5). The part of the warehouse where
the boxes will be placed on the belt must also be set in depth, length towards the
box. This can be done by releasing a button (6) and moving the entire structure
forwards or backwards. The push-in cylinder (7) must also be adjusted in length so
that the pusher pushes the box far enough. In addition, the pusher can also be set in
width direction (8), but that depends on the change in width.

1 2 3 7 5

6 4 8

Convert to another product 28

Manual .ASP

6.9 BOXES CLAMP AND BOXES OPENER

When the boxes are placed on the vacuum rim, they are opened. This is done by
means of a clamp and an opener. The clamp tightens the box against a certain
shape, causing the lock of the box to open. Then comes the opener and it pushes
open the lid of the box and guides it until the lid is in some kind of guide. The clamp
can be adjusted in length by means of a button (1) and different attachments can be
placed on the clamp. This has to do with whether the boxes are made of plastic,
cardboard or tin. But these attachments are part of the format parts. The same goes
for the opener. This can also be adjusted but also contains an attachment (2) which
can differ per type of box.

1 2

Convert to another product 29

Manual .ASP

6.10 CIGAR PUSHER

The pusher, which pushes cigars into the box and then serves as a guide, has the
pusher in itself as a size part (1). This part must be exchanged per size box. In
addition, this unit has several things that need to be set up. The position, angle and
length of the size part can be determined by means of a simple screw connection (2).
In addition, it is possible to determine the movement of the pusher. By means of bolt
(3) and (4) the arm can be steered well independently of the curve movement.

1 2 3 4

Convert to another product 30

Manual .ASP

BACK GUIDE, PAPER FOLDER AND BOXES SHUTTER

The lids of the boxes pass through a back guide during transport (1). This way the
box stays open. Depending on the type of box, cardboard, can or plastic, the lid
sometimes wants to close on its own. This back guide is adjustable, but in practice it
will not be adjusted often. When the lid comes out of the back guide, the paper on the
front still needs to be folded over. This is done by means of a paper folder (2). This is
adjustable in height so that the folder can fold well over the box. Immediately after
folding, the lid is also closed if it is not yet closed by itself. This is done through the
boxes shutter (3). The lid is then closed on the box with the paper folded. The
cylinder of the pusher (4) presses the lid back into the lock so that the box is ready to
stack.

1 4 2 3

Convert to another product 31

Manual .ASP

6.11 STACKER AND FULL BOX WAREHOUSE

The stacker of the ASP consists of 2 stacking plates (1) that must be adjusted to the
correct pitch. This can be done by moving it in the slobber holes. The warehouse can
be adjusted in its entirety. From the operator's point of view, the left (2) and the front
(3) are the 0-line. In addition, it is possible to adjust the width of the magazine by
shifting the entire adjustable angle complete with brushes (4). The back wall (5),
which depends on the length of the box, can be adjusted by turning the handwheel
(6). Finally, the pusher (7) should be adjusted so that it pushes into the middle of the
full stack.

7 2 1 3 4 5 6

Convert to another product 32

Manual .ASP

7 ADJUSTMENTS AND ADJUSTMENTS, MALFUNCTIONS AND

MAINTENANCE

7.1 OPERATOR PANEL

The operator panel is used to change settings and to read production data and the
status of the machine. The malfunctions and alarms are also displayed.
After the main switch is turned on, the control program starts automatically.
Below is the main menu of the operator panel.

The current status of the machine and the number of boxes since the last reset are
continuously displayed.

7.1.1 KEYS/INFORMATION DISPLAYED ON THE MAIN SCREEN

7.1.1.1 MENU KEYS

The menu keys are displayed at the top left. By pressing these buttons, the display
jumps to the page of the respective function.

Main

Production data

Institutions

Service

Adjustments and adjustments, malfunctions and maintenance 33

 Manual .ASP

7.1.1.2 FUNCTION KEYS

The function keys must be green during normal production.

DOOR LOCK OFF/ON

By pressing the function button, the doors can be unlocked and
,
locked. When the doors are unlocked, the symbol changes from
green to red. In addition, it is possible to unlock the doors by
pressing the STOP button 0.5 s.
DEFLATING MASSFLOW
By pressing the button, the drain control in the mass flow is
,
disabled. This can be useful if the mass flow needs to be
emptied. If the control is disabled, the button will turn red and
flash. By pressing the button again, it will turn green and the
control will be enabled again.
EMPTYING CIGAR BUFFER
Pressing the button disables the drain control in the cigar buffer.
,
This can be useful if the buffer needs to be emptied. If the control
is disabled, the button will turn red and flash. By pressing the
button again, it will turn green and the control will be enabled
again.
BLOCK INPUSHERS
By pressing the button, the pushers are blocked. This can be
,
useful if the machine needs to be emptied. If the pushers are
blocked, the button will turn red and flash. By pressing the button
again, it turns green and the pushers will push cigars back into the
container belt.

7.1.1.3 POP-UP MENU BUTTON

By pressing this button, a pop-up menu with multiple buttons will appear. Via this
quick menu it is possible to change the language as well as log out.

To change the language permanently, choose the chosen language and

Warning!
then go to the service screen and exit the runtime. Then restart it.

Pressing the or - button closes the quick menu.

Adjustments and adjustments, malfunctions and maintenance 34

Manual .ASP

7.1.1.4 INFORMATION
Status

Stopped Stopped due to malfunction

Warning In production but without intervention, this leads to a

malfunction
Standby Ready for production but waiting for e.g. import products

Production Machine in operation

Speed and position

Active alarms
Active alarms are shown on the main screen by means of a pop-up screen.

Another possibility to display the alarms is by using the button. This button
is available in every screen. By pressing the button, an extra screen is displayed on
the left side in which all active alarms are displayed.

Adjustments and adjustments, malfunctions and maintenance 35

Manual .ASP

7.1.2 MENU [PRODUCTION DATA]

By pressing the menu key , the following screen appears:

This screen displays the following information:

- The daily counter of the number of products produced
- The daily counter of the number of operating hours.
- The total numerator of the number of products produced
- The total counter of the number of operating hours.
- Error in the number control of the top layer at the camera and the instoter.
- Error in the number of control of the bottom layer at the camera and the
instoter.

The daily counters can be reset, the total counters cannot.

Via this screen you can also go to the alarm-logging pages:

Adjustments and adjustments, malfunctions and maintenance 36

Manual .ASP

This screen displays an overview of all alarms. It shows how often and the time
they've been active. Use the chapter Alarm analysis (7.2) to find out the meaning of
the emergency numbers.

There are multiple pages to log all alarms. Via the 'Reset alarm logging' button, the
counters of all alarms are reset to 0.

7.1.3 [SETTINGS] MENU

Pressing the menu key [ ] in the main menu takes you to the settings
menu. However, this page is protected with a password.

The password is: 100

(If the settings menu is selected again for 10 minutes, the password does not have to
be entered again)
After entering the correct password, the following screen appears:

Adjustments and adjustments, malfunctions and maintenance 37

Manual .ASP

7.1.3.1 SUBMENU [RIDGE SETTINGS]

The ASP is a so-called rotating machine; i.e.dat this machine contains a main shaft
that drives a number of mechanically branched parts and produces one product
during each revolution. A number of auxiliary drives can also be controlled via this
settings menu. The [START] and [STOP] fields indicate the encoder mode in which
the respective control is switched on and off respectively. The current encoder
position of the main axis can also be read.

Controls were provided for various components.

Cam control

Adjustments and adjustments, malfunctions and maintenance 38

Manual .ASP

This function controls a component from a start value to a stop value.

Cam pulse
With this function, a check or control is carried out at 1 moment. Moment of
checking/executing is entered.

7.1.3.2 SUBMENU [OTHER]

By pressing the button , the following screen appears:

In this screen you can enter the high and low speed of the machine (Hare and turtle).

Auxiliary drives: the input and exit time of the auxiliary drives can be entered.
Auxiliary drives include fans and vacuum pumps. Before the main drive can start
running, the auxiliary drives must be at revs. If the main engine is stopped, the
auxiliary drives can also stop over time.

Repeat counters: The error repeaters indicate how many times an error can occur
before an alarm is generated.

Number of cycles of tilt shafts: The number of times the magazine must shake to
improve the falling of the cigars.

Camera control: Here there is the possibility to turn the camera control on/off.

Paper insert: The paper insert can be switched on/off. In addition, there are 2 modes
to choose: fixed continuation length and print mark reader.
If you want to insert a fixed length of paper, you can switch off the print mark reader.
A value can be entered by the user in the parameter "length".

If one chooses the option of printing brand, a sensor is used to look at where the
printing mark is located and the paper is transported through a fixed length.

Adjustments and adjustments, malfunctions and maintenance 39

Manual .ASP

Note: The motor has built-in deceleration and acceleration values, if one sets the
distance of continuation after detecting the print mark too short, this can cause
problems with the paper insert. These values were chosen in such a way that the
paper is not broken. If you set this value too small, you have the problem that the
engine wants to turn backwards and therefore crashes because of the return
protection.

Laser: This parameter allows the laser to be switched on/off.

Massflow: This parameter can be used to enable/disable the mass flow.

Block puncture unit below: With this parameter, the puncture unit at the bottom may
or may not be blocked.

Repeat counter blowing off prick cubes: This counter indicates the number of cycles
the prick cubes are blown off.

7.1.4 MENU [SERVICE]

Pressing the function button in the main menu takes you to the service
menu. However, this page is protected with a password.

The password is: 100

(If the service menu is selected again for 10 minutes, the password does not have to
be entered again)
After entering the correct password, the following screen appears:

Adjustments and adjustments, malfunctions and maintenance 40

Manual .ASP

7.1.4.1 SUBMENU [STATUS INPUTS/OUTPUTS]

By pressing from the service menu, the following screen appears:

In this screen, the first 16 inputs of the PLC are shown with the current status. If
desired, use the electrical diagram to find the desired input.
By pressing the button card or unit, the corresponding screen appears.

Adjustments and adjustments, malfunctions and maintenance 41

 Manual .ASP

7.1.4.2 SUBMENU [FORCE OUTPUTS]

By pressing from the service menu, the following screen appears:

When this screen is selected, the normal PLC program will be interrupted!

In this screen, the outputs of the PLC can be controlled manually. Press to
force the corresponding output to ON.
By pressing again, the output is turned OFF again.

By pressing, the corresponding output will be forced, during the time that the
button is operated.

In the sub-menu force outputs all outputs can be controlled manually.

This can lead to very dangerous situations. The service technician must
Warning! always convince himself that there are no people working in the
machine. The machine must therefore be trimmed with red and white
ribbon.

By selecting the right cards/units, you can control the corresponding outputs

7.1.4.3 SUBMENU [NETWORK LAYOUT]

Pressing the button takes you to the overview screen of the machine
network. This shows which participants are "Live" (green color = Live, Red = not
present / interference).

Adjustments and adjustments, malfunctions and maintenance 42

Manual .ASP

7.1.4.4 SUBMENU [SERVO]

In this screen, settings of the servos can be changed.

However, setting the zero point requires an additional action: an additional

button is placed at the bottom of the screen. This must first be pressed before
the buttons for setting the zero point appear.

The setting options are as follows:

Adjustments and adjustments, malfunctions and maintenance 43

 Manual .ASP

X-Offset This is a shift of the selected The higher the

servo compared to the virtual value, the further
master. the current servo
will be behind in
terms of timing.
Y-Offset This is a shift in position The higher the
relative to its own internal curve value, the further
the servo will
continue.
Y-scale This is a scale factor of the The higher the
internal curve. value, the further
the servo will
continue.
This symbol indicates whether When the drive is
or not the servo is referenced initialized for the
(i.e. has a verified zero first time or after
position). disconnecting the
Green = valid position encoder cable, the
Red = invalid position servo loses its zero
point and must be
reset to it.
This symbol indicates whether After an STO
the controller has reached its (doors opened or
starting position and is emergency stop),
therefore synchronized with the this state first
virtual master. becomes active so
Green= synchronized that all drives are
Red = not yet synchronized first put in position.
This symbol indicates that the
servo is paired and ready to
rotate with the virtual master
Green= In Lock
Red = not in lock
Button to set the 0 position. Place the drive on
Only visible when the release the engraved zero
button is pressed at the bottom. point, then press
this button. This
sets the zero point.
Enable of the servo. The servos can be
manually enabled.

Application:
X-offset can be used to shift the chain in timing (earlier transport).

Y-offset can be used to change the position of the chain relative to the main shaft.

Y-scale does not apply to this machine.

Warning! Adjusting the home position of a servo can affect the timing of the entire
machine. Make sure that, when the home position is recorded on the
screen, the relevant servo is actually at its mechanical reference

Adjustments and adjustments, malfunctions and maintenance 44

Manual .ASP

position.

7.1.4.5 TEST PRODUCTION

By pressing the function key / the production mode can be changed.

The test mode is intended to adjust the machine without a product; The product
checks are not active. If the machine is in test mode, the page background will
change to a yellow color. Also, the bottom bar will flash in an orange color. If the
machine is in production mode, the page background will have a gray color. The
mode PRODUCE is the normal state of production.

7.1.4.6 VERSION INFORMATION

In this window you can find the current version number. The machine identification
can be filled in by the user by typing text in the blue input field.

7.1.4.7 CHANGE PASSWORD

Here you can change the password required to log in to the settings and service
pages.

7.1.4.8 RUNTIME TERMINATION

To terminate the runtime, you can enter the password.
Password: atdserv

Adjustments and adjustments, malfunctions and maintenance 45

Manual .ASP

7.1.4.9 ADJUST DATE/TIME

The current date and time can be adjusted via the hmi.

7.1.4.10PRODUCT REGISTER
Pressing the - button will take you to the following screen:

Centrally one can see which detections and checks have been carried out and
approved (green dots). If you manually take a product off the line, you have to click
on the relevant ball. As a result, the sphere will turn red and the controls for this
product will be switched off. If you manually place a product in an empty place in the
machine, you must also click on the relevant sphere. As a result, the sphere will turn
green and the controls for this product will be activated.

Adjustments and adjustments, malfunctions and maintenance 46

 Manual .ASP

7.2 ALARM ANALYSIS

The table below gives an overview of all alarm messages, their cause and the
possible solution. For all alarms, the alarm is reset by removing the cause and then
operating the [START] push button.
The alarms are divided into three categories:
 Big alarm :The entire machine is stopped immediately.
 Small alarm : One part of the machine stops, if possible the rest of the
machine will continue to run.
 Warning: a notification that may eventually generate an alarm; The
machine will continue to run for the time being.

Before maintenance is carried out, the machine must be secured. This

means that the main switch is locked in the OFF position with the
personal padlock of the maintenance technician. The air supply is also
Warning!
turned off. If this is not possible due to the work, the maintenance
technician is responsible for the safety of all employees in the vicinity of
the machine.

Alarm Cause Solution

001. Emergency stop
002. Security doors
opened
003. Thermal failure
004. Insufficient
compressed air pressure
The emergency stop relay is Unlock all emergency stop
switched off, due to an pushers. Press [START] to turn
emergency stop situation or due on the emergency stop relay.
to the machine switching on.
One of the security doors is Close all security doors. Press
open. [START] to turn on the door
relay.
A thermal protection of a motor Check the respective motor
in the control cabinet is disabled and drive. Restore thermal
by an overload. protection.
Then press [START].
The compressed air pressure Check the compressed air
has dropped below the supply and the main valve.
workable minimum. Then press [START].

006. Error FQI Supply
empty boxes
007. Error FQI Massflow
009. Network error
The regulator of the box supply
has malfunctioned.
The massflow regulator has
malfunctioned.
If a certain participant in the
network is not online, this
message will be displayed.
Check which malfunction is
listed on the display, fix it.
Restart the controller, or turn
the machine off and on again.
Then restart the machine.
Check which malfunction is
listed on the display, fix it.
Restart the controller, or turn
the machine off and on again.
Then restart the machine.
Check why a participant is not
online. Check the connections.
If necessary, restart the
machine. If it is not resolved,
contact a maintenance
technician.

Adjustments and adjustments, malfunctions and maintenance 47

 Manual .ASP

012. Servo fault main The servo controller is in On the display of the regulator,
motor malfunction. check what the malfunction is,
fix it. Then press [START].

013. Servo main engine The servo motor does not yet Set the engine to its zero point
unreferenced have a zero point. and learn this via the service
menu.

014. Servo main drive The overload protection of the Check if a blockage has
overload servo has been addressed. occurred, remove it, and then
press [START].

017. Servo: Not all One or more drives are not Make sure the drives are
controls enabled enabled. enabled (via the service menu).

018. Servo: One or more drives did not get Check if a blockage has
Synchronisatie of lock to their position within a certain occurred, remove it, and then
time-out time. press [START].

022. Servo error transport The servo controller is in On the display of the regulator,
cigars malfunction. check what the malfunction is,
fix it. Then press [START].

023. Servo transport The servo motor does not yet Set the engine to its zero point
cigars not referenced have a zero point. and learn this via the service
menu.

024. Servo transport cigar The overload protection of the Check if a blockage has
overload servo has been addressed. occurred, remove it, and then
press [START].

027. Servo error transport The servo controller is in On the display of the regulator,
boxes malfunction. check what the malfunction is,
fix it. Then press [START].

028. Servo transport The servo motor does not yet Set the engine to its zero point
boxes not referenced have a zero point. and learn this via the service
menu.

029. Servo transport The overload protection of the Check if a blockage has
boxes overload servo has been addressed. occurred, remove it, and then
press [START].

Adjustments and adjustments, malfunctions and maintenance 48

 Manual .ASP
032. Servo error paper The servo controller of the
input paper feeder is in malfunction.
Drive fault: "following error"
If you run with printing brand
paper and set the trailing length
too small, it could be that this
error occurs. Because the
deceleration is limited (so as not
to tear the paper), it may be that
the engine first turns too far and
then wants to turn back, which
is not possible because of the
return block.
033. Servo paper feeder The servo motor does not yet
unreferenced have a zero point.
034. Servo paper feed The overload protection of the
overload servo has been addressed.
035. Massflow empty The funnel of the mass flow is
deflated, the mass flow will stop
transporting.
Detection is based on a sensor.
036. Supply warehouse The buffer above the
cigars ASP empty warehouses has been deflated.
This is done on the basis of the
sensor at the top + X cycles.
043. Overload instoter The pusher of the cigars has
cigars in box become overloaded and has
disconnected himself.
044. Box not opened The box has not been opened Check why the box was not
so that no cigars can be pushed opened, fix the problem.
in. Then press [START].
Adjustments and adjustments, malfunctions and maintenance
On the display of the regulator,
check what the malfunction is,
fix it. Then press [START].
Following error:
Make the length larger,
adjust the sensor if
necessary.
Set the engine to its zero point
and learn this via the service
menu.
Check if a blockage has
occurred, remove it, and then
press [START].
Refill the cigars in the
warehouse. If you want to
empty the mass flow,
deactivate the mass flow using
the button on the main screen.
Refill the cigars in the
warehouse. If you want to
empty the machine, deactivate
the buffer using the button on
the main screen.
Check for any blocks, and then
check the link. If the clutch is
disconnected, it must be
manually returned to the
correct position.
Then press [START].
49
 Manual
045. Photocell box
opened error
046. Insufficient cigars in
box
047. Sensor number
control cigars error
048. No paper present in
box
049. Photocell paper in
box error
050. Destacker empty
051. Boxes warehouse
fully loaded
052. Duration of instoter
destacker exceeded
053.Expiry of rejection
054.Monitoring top guide
box
Adjustments and adjustments, malfunctions and maintenance
.ASP
The photocell for checking
whether the box is open
remains activated (always sees
a box)
The sensor for the detection
when inserting the cigars into
the box has detected too few
cigars.
The sensor for detection when
"inserting the cigars into the
box" remained high for a full
cycle.
The sensor that checks whether
paper has been placed in the
box has detected that no paper
is present.
The sensor for detecting "paper
present" has remained high for
a full cycle.
The destacker of the empty
boxes no longer has any
products to prepare for
transport.
The sensor on the output side –
full boxes of warehouse – of the
machine is operated.
Pushing the empty boxes to the Check if there is a blockage for
conveyor belt is blocked. As a the instoter, take it away.
result, the pusher cannot finish Then press [START].
his stroke in time and an alarm
is created.
The rejection cylinder has
experienced a blockage. As a
result, the cylinder cannot finish
its stroke in time and an alarm is
created.
The guide above the filled box is
pushed upwards, probably
because a box is not closed
properly.
Check that the sensor is not
covered. Take this away.
Then press [START].
Check why the sensor detects
too few cigars. Check the
warehouse for a blockage so
that not enough cigars are
supplied.
Check the sensors to make
sure they detect properly.
Then press [START].
Check why the sensor
remained activated. Remove
the blockade.
Then press [START].
Check the sensor adjustment.
Then press [START].
Contamination of the sensor
may have occurred. Take away
this pollution.
Then press [START].
Refill the empty boxes
warehouse.
Then press [START].
There are products in front of
the sensor, take these products
away.
Then press [START].
Check if there is a blockage at
the rejection, remove it.
Then press [START].
Close the box manually or take
it away.
Then press [START].
50
 Manual .ASP

058. Laser offline The laser is not online. Check the laser. Then press
[START].

060. Laser did not laser The laser did not mark it. Check the laser. Then press
[START].

061. Smoke extraction The filter of the smoke Replace the filter. Then press
laser: filter full extraction is full. [START].

062. Camera bottom layer The camera for the number Check the camera. Then press
offline control of the bottom layer is [START].
offline.
063. Camera bottom layer The bottom layer number Check the camera. Then press
not ready for use control camera is not in [START].
production mode.
064. Camera bottom layer The camera for the number Check the number of cigars in
error cigar recognition control of the bottom layer has the container belt. Check the
detected an error. cigar warehouse. Then press
[START].
065. Camera top layer The top layer number control Check the camera. Then press
offline camera is offline. [START].

066. Camera top layer not The top layer number control Check the camera. Then press
ready for operation camera is not in production [START].
mode.
067. Camera top layer The top layer count camera has Check the number of cigars in
error cigar recognition detected an error. the container belt. Check the
cigar warehouse. Then press
[START].
068. Camera bottom layer The cigars were not taken Check the sliding plate. Then
slide plate not free away. press [START].

069. Camera top layer The cigars were not taken Check the sliding plate. Then
sliding plate not free away. press [START].

071. Overload cigar The pusher of the cigars has
pusher bottom layer become overloaded and has
disconnected himself.
Check for any blocks, and then
check the link. If the clutch is
disconnected, it must be
manually returned to the
correct position.
Then press [START].

072. Overload cigar The pusher of the cigars has
pusher top layer become overloaded and has
disconnected himself.
Check for any blocks, and then
check the link. If the clutch is
disconnected, it must be
manually returned to the
correct position.
Then press [START].

073. Sensor error cigar The sensor has remained high Contamination of the sensor
pusher bottom layer for a full cycle. may have occurred. Take away
this pollution.
Then press [START].

Adjustments and adjustments, malfunctions and maintenance 51

 Manual .ASP

074. Sensor error cigar The sensor has remained high Contamination of the sensor
pusher top layer for a full cycle. may have occurred. Take away
this pollution.
Then press [START].

075. Running time The cylinder for blocking the Check if there is a blockage,
overrun cylinder box feed is experiencing a remove it.
blocking box entry blockage. As a result, the Then press [START].
cylinder cannot finish its stroke
in time and an alarm is created.
076. Duration overrun The movement before closing Check if there is a blockage,
closing box the box experiences a blockage. remove it.
As a result, the cylinder cannot Then press [START].
finish its stroke in time and an
alarm is created.
077. Closing the box The movement before pressing Check if there is a blockage,
exceeding the duration the box is blocked. As a result, remove it.
the cylinder cannot finish its Then press [START].
stroke in time and an alarm is
created.
078. No release of The downstream machine does The ASP starts automatically
downstream machine not release. after the downstream machine
releases.
079. Emergency stop The emergency stop button of a Unlock the emergency stops,
caused by other machine in the line is pressed. then press [START].
machine
080. Emergency stop 1 Emergency stop button 1 was Turn it half a turn to unlock it.
pressed pressed Then press [START].

084. Door 1 opened Door 1 is open. If the machine is When closing this door, the
in production, it will be stopped. warning will disappear. Then
press [START].

Adjustments and adjustments, malfunctions and maintenance 52

 Manual .ASP

7.3 MALFUNCTIONS NOT DISPLAYED BY THE INSTALLATION

Disturbance Cause Solution

Machine is off, but does
Main switch is off. Turn on the main switch.
not start.
Check the protections in
Tension has dropped.
the control cabinet.
[START] button flashes,
but pressing [START] does Remove the cause of the
Another alarm is active
not switch the installation alarms.
to automatic operation.

If a malfunction occurs that cannot be solved by you, but for which a

Tip!
service technician must come, make a note of the malfunction.

Think of:
- What was the situation, before the failure occurred.
- What is the possible cause of the malfunction.
- What have you tried to fix the malfunction yourself.
- What did you do, after you could not solve the malfunction yourself.

Adjustments and adjustments, malfunctions and maintenance 53

Manual .ASP

8 BELONG

8.1 PNEUMATIC DIAGRAM

680001491 ASP

8.2 SPARE PARTS LIST

692841237 ASP

8.3 FORMAT PARTS LIST

8.4 LUBRICATION SCHEME

680001492 Lubrication scheme ASP 274-272

Belong 54
Manual .ASP

9 KEYWORD LIST, ICONS, ATTACHMENTS

9.1 GLOSSARY

9.2 ICONS

9.3 ATTACHMENT

Keyword list, icons, attachments 55