Manual Kiefel

Operating instructions
G030

KIRION
Kirion C Operating Instructions
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091001_G030_001_UKrevised.doc
G030
 .............................................................................................................. 1
KIRION
KIRION C OPERATING INSTRUCTIONS............................................................ 1
1 INTRODUCTION ........................................................................................... 8
2 SCREEN STRUCTURE................................................................................. 8
2.1 Header line....................................................................................................................................... 8
2.2 Footer line ........................................................................................................................................ 9
2.3 Overview screen ............................................................................................................................ 10
3 OPERATION ............................................................................................... 11
3.1 Extruder......................................................................................................................................... 11
3.1.1 Extruder drive............................................................................................................................. 11
3.1.1.1 Alarms............................................................................................................................... 12
3.1.1.2 Start conditions ................................................................................................................. 12
3.1.2 Extruder melt pressure and temperature ..................................................................................... 13
3.1.2.1 Extruder melt pressure alarms........................................................................................... 14
3.1.3 Extruder grooved bushing cooling/heating unit ......................................................................... 15
3.1.3.1 Extruder grooved bushing heating/cooling unit alarms .................................................... 15
3.1.4 Extruder edge trim return ........................................................................................................... 15
3.2 Cooling ring and IBC blower ....................................................................................................... 17

3.2.1 Alarms ........................................................................................................................................ 18
3.2.2 Start conditions........................................................................................................................... 18
3.2.3 Cooling unit................................................................................................................................ 18
3.2.4 Alarms ........................................................................................................................................ 18
3.3 USB................................................................................................................................................. 19
3.3.1 Functional principle.................................................................................................................... 19
3.3.2 Alarms ........................................................................................................................................ 19
3.4 Calibration basket ......................................................................................................................... 20

3.4.1 Alarms ........................................................................................................................................ 20
3.4.2 Calibration basket diameter display ........................................................................................... 20
3.4.3 Calibration basket height display ............................................................................................... 20
3.5 Bubble breakage monitoring........................................................................................................ 21

3.5.1 Web break monitor alarms ......................................................................................................... 21
3.6 Width measurement...................................................................................................................... 22

3.6.1 Width measurement alarms ........................................................................................................ 22
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3.7 Width regulation ........................................................................................................................... 24

3.7.1 Width regulation alarms ............................................................................................................. 24
3.8 Take-off .......................................................................................................................................... 25

3.8.1 Take-off drive............................................................................................................................. 26
3.8.1.1 Take-off alarms................................................................................................................. 27
3.8.2 Take-off reversal ........................................................................................................................ 28
3.8.2.1 Take-off reversal alarms ................................................................................................... 28
3.8.3 Take-off turning bars.................................................................................................................. 28
3.8.4 Take-off turning bar blower ....................................................................................................... 29
3.8.5 Take-off layflat display .............................................................................................................. 30
3.8.6 Take-off gusset up / down or side guide..................................................................................... 30
3.8.7 Take-off centring guide .............................................................................................................. 31
3.8.8 Take-off auxiliary basket............................................................................................................ 31
3.8.8.1 Take-off auxiliary basket alarms....................................................................................... 32
3.8.9 Take-off tempering unit.............................................................................................................. 32
3.8.9.1 Take-off tempering unit alarms......................................................................................... 32
3.8.10 Take-off intermediate take-offs ............................................................................................. 33
3.9 Dosing............................................................................................................................................. 34
3.9.1 Extruder dosing regulation ......................................................................................................... 35
3.9.1.1 Extruder dosing intended throughput................................................................................ 36
3.9.2 Material pre-selection................................................................................................................. 36
3.9.3 Continuous dosing ...................................................................................................................... 39
3.9.3.1 Continuous dosing feed rates and speed controls.............................................................. 40
3.9.3.2 Continuous dosing material pre-selection......................................................................... 41
3.9.3.3 Dosing worms ................................................................................................................... 42
3.9.3.4 Continuous dosing alarms................................................................................................. 43
3.9.4 Charge dosing (batch) ................................................................................................................ 47
3.9.4.1 Charge dosing feed rates and speed controls .................................................................... 48
3.9.4.2 Charge dosing material pre-selection and handling .......................................................... 48
3.9.4.3 Charge dosing mixer ......................................................................................................... 50
3.9.4.4 Charge dosing alarms........................................................................................................ 50
3.10 Winder............................................................................................................................................ 64
3.10.1 WM winder............................................................................................................................ 64
3.10.2 WS winder ............................................................................................................................. 65
3.10.3 Winder overview ................................................................................................................... 66
3.10.3.1 Winder metre counter ....................................................................................................... 67
3.10.4 Winder drives and settings..................................................................................................... 69
3.10.4.1 Winder's intermediate take-off drive (IS) ......................................................................... 69
3.10.4.2 Winder's primary nip drive PN ......................................................................................... 70
3.10.4.3 Winder's cooling roller train drive CW............................................................................. 70
3.10.4.4 Winder's trim nip drive TC ............................................................................................... 70
3.10.4.5 Winder's spreader cooling roller train drive STC ............................................................. 71
3.10.4.6 Winder's spreader drive SWD........................................................................................... 71
3.10.4.7 Winder's winding station drive WD.................................................................................. 71
3.10.4.8 Winder's central drive CD................................................................................................. 71
3.10.5 Winder operational modes ..................................................................................................... 72
3.10.5.1 Winder contact winding mode .......................................................................................... 74
3.10.5.2 Winder contact angle mode + CLP ................................................................................... 74
3.10.5.3 Winder contact angle mode + CLP + central drive mode ................................................. 75
3.10.5.4 Winder gap winding mode................................................................................................ 76
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3.10.6 Winder diagrams.................................................................................................................... 77

3.10.7 Winder accessories ................................................................................................................ 78
3.10.7.1 Winder vacuum pump....................................................................................................... 78
3.10.7.2 Winder traverse and longitudinal oscillation .................................................................... 79
3.10.7.3 Winder trim-strip vacuum................................................................................................. 79
3.10.7.4 Winder roller cooling........................................................................................................ 80
3.10.7.5 Rotary winder support legs ............................................................................................... 80
3.10.7.6 Winder shaft supports ....................................................................................................... 80
3.10.7.7 Winder winding direction ................................................................................................. 80
3.10.7.8 Winder tempering units..................................................................................................... 81
Winder roll change ................................................................................................................................... 82
3.10.7.9 Winder status display........................................................................................................ 82
3.10.8 Winder fault messages........................................................................................................... 83
3.11 Recipes............................................................................................................................................ 94
3.11.1 Recipe handling ..................................................................................................................... 96
3.12 Trend .............................................................................................................................................. 97

3.12.1 Trend selection ...................................................................................................................... 98
3.12.2 Trend alarms .......................................................................................................................... 99
3.13 Pellet supply................................................................................................................................. 100

3.13.1 Pellet supply alarms............................................................................................................. 101
3.14 Heating ......................................................................................................................................... 102

3.14.1 Heating alarms..................................................................................................................... 102
3.15 Profile measurement and control............................................................................................... 105

3.15.1 Profile measurement ............................................................................................................ 105
3.15.1.1 Profile measurement alarms............................................................................................ 106
3.15.1.2 2 Sigma ........................................................................................................................... 108
3.15.2 Profile control alarms .......................................................................................................... 109
3.16 Alarm display .............................................................................................................................. 110

3.16.1 Alarm handling .................................................................................................................... 111
3.17 Order ............................................................................................................................................ 113

3.17.1 Details of order .................................................................................................................... 115
3.17.1.1 Roll report....................................................................................................................... 116
3.18 Residual quantities management ............................................................................................... 117

3.18.1 Residual quantities management alarms.............................................................................. 119
3.19 Week and month report.............................................................................................................. 120
3.20 Production protocol .................................................................................................................... 121

3.20.1 Production protocol history ................................................................................................. 123
3.21 Servicing....................................................................................................................................... 124
3.22 Elapsed time counter................................................................................................................... 125
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4 SERVICE AND PARAMETER SETTINGS................................................ 126
4.1 Password entry ............................................................................................................................ 126
4.2 General parameters .................................................................................................................... 127

4.2.1 Language selection ................................................................................................................... 127
4.2.2 Units of measure selection........................................................................................................ 127
4.3 Extruder....................................................................................................................................... 128

4.3.1 Extruder designations ............................................................................................................... 128
4.3.2 Extruder drives ......................................................................................................................... 128
4.3.3 Extruder melt pressure.............................................................................................................. 129
4.3.3.1 Extruder melt pressure calibration .................................................................................. 129
4.3.4 Extruder pellet monitoring ....................................................................................................... 130
4.3.5 Extruder grooved bushing tempering unit ................................................................................ 130
4.4 Cooling ring and IBC blower ..................................................................................................... 131

4.4.1 USB blower regulation ............................................................................................................. 131
4.4.2 Cooling units ............................................................................................................................ 132
4.5 USB............................................................................................................................................... 133

4.5.1 USB valve ................................................................................................................................ 133
4.5.2 USB sensor ............................................................................................................................... 133
4.5.3 USB regulation parameters....................................................................................................... 134
4.5.4 USB blower regulation ............................................................................................................. 134
4.6 Calibration basket ....................................................................................................................... 135

4.6.1 Calibration basket with diameter acquisition ........................................................................... 135
4.6.2 Calibration basket without diameter acquisition ...................................................................... 136
4.6.3 Calibration basket with cage height display ............................................................................. 137
4.7 Width measurement.................................................................................................................... 138

4.7.1 Width measurement status display ........................................................................................... 138
4.8 Width regulation ......................................................................................................................... 139
4.9 Take-off ........................................................................................................................................ 140

4.9.1 Take-off reversal ...................................................................................................................... 140
4.9.2 Take-off layflat display ............................................................................................................ 140
4.9.3 Take-off central guide display.................................................................................................. 140
4.9.4 Take-off gusset or side guide display ....................................................................................... 141
4.9.5 Take-off tempering unit............................................................................................................ 141
4.10 Dosing........................................................................................................................................... 142

4.10.1 Shrinkage calculation........................................................................................................... 142
4.11 Winder.......................................................................................................................................... 143

4.11.1 WM winder.......................................................................................................................... 143
4.11.2 WS winder ........................................................................................................................... 145
4.12 Pellet supply................................................................................................................................. 146

4.12.1 Pellet supply hopper feed time............................................................................................. 146
4.12.2 Pellet supply warning .......................................................................................................... 146
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4.12.3 Pellet supply blower settings ............................................................................................... 146

4.12.4 Pellet supply cleaning function............................................................................................ 147
4.12.5 Pellet supply residual quantities management ..................................................................... 147
4.13 Heating ......................................................................................................................................... 148

4.13.1 Heating zone minimum and maximum setpoints................................................................. 148
4.13.2 Heating general shutdown ................................................................................................... 148
4.13.3 Heat-up ................................................................................................................................ 149
4.13.4 Heating zone activation ....................................................................................................... 150
4.13.5 Heating zone temperature settings ....................................................................................... 150
4.13.6 Heating zone temperature enable......................................................................................... 151
4.13.7 Heating zone control parameters ......................................................................................... 151
4.13.7.1 Heating zone control parameter optimisation ................................................................. 151
4.13.8 Heating zone current monitoring ......................................................................................... 153
4.14 Profile ........................................................................................................................................... 154

4.14.1 Profile measurement parameters.......................................................................................... 154
4.14.1.1 Profile measurement correction factor ............................................................................ 154
4.14.2 Profile regulation offset ....................................................................................................... 154
4.14.2.1 Profile regulation offset setting at C2 and C3 ................................................................. 155
4.14.2.2 Profile regulation offset setting at C1 ............................................................................. 157
4.14.3 Profile regulation parameters............................................................................................... 157
4.14.3.1 Profile regulation stability criterion parameters.............................................................. 158
4.14.4 Profile regulation actuator function monitoring / current measurement .............................. 158
4.14.5 Profile history ...................................................................................................................... 159
4.15 Plant stop ..................................................................................................................................... 160

4.15.1 Web break............................................................................................................................ 160
4.15.2 Defects in film composition................................................................................................. 161
4.16 Alarms .......................................................................................................................................... 162

4.16.1 Alarm classification ............................................................................................................. 162
4.16.2 Customer alarms .................................................................................................................. 163
4.17 Material database........................................................................................................................ 164
4.18 Supplementary functions and information ............................................................................... 166

4.18.1 Back up recipes.................................................................................................................... 166
4.18.2 Base parameters ................................................................................................................... 166
4.18.3 Versions ............................................................................................................................... 168
4.18.4 Printer .................................................................................................................................. 168
4.18.5 PLC...................................................................................................................................... 169
4.18.5.1 PLC ................................................................................................................................. 169
4.18.6 Lamp-check ......................................................................................................................... 170
4.18.7 Print roll report .................................................................................................................... 170
4.19 PC Functions ............................................................................................................................... 171

4.19.1 Touch calibration................................................................................................................. 171
4.19.2 Time and region settings...................................................................................................... 171
4.19.3 Emergency operation ........................................................................................................... 172
5 ALARM LIST ............................................................................................. 175

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1 Introduction
This documentation describes the functional operation of a Kirion system.
All Kirion system options are presented and described. Some options may
not be present in a particular system.
2 Screen structure
Every screen is divided into 3 areas:
• header line
• system operation
• footer line
2.1 Header line
• Display of the KC serial number.

This number makes it possible for Kiefel to verify the system.
• Password entry
These fields display

• width value [mm] [in]
• take-off speed [m/min] [ft/min]
• throughput [kg/h] [lbs/h]
• order setpoint value and actual value [m] [ft]
• film thickness [µm] [mil]
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Prints the displayed screen page (screenshot)
Calls up online help. Online help explains the function of the

displayed screen
Calls up Dr. Wise. Dr. Wise helps to answer technical

process questions
2.2 Footer line

The footer line is filled with function controls. A function control can cause the
display to change to a different screen page or also start a motor.
If a function control has a bright background, it is enabled for activation.

There are more function controls.
There are more function controls.
Change to the next higher menu level.
Before a value can be changed, this control (enable) must

be activated.
If the enabled control has a bright background, it can be
activated.
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2.3 Overview screen
This screen is always displayed just after the computer

has booted or following (repeated) activation of the "Up"
arrow control.
Important
If profile regulation is available, this field will show the type of die-head or type of
cooling ring. The last digit indicates the number of regulated zones.
This display is generated by a coded connector.
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3 Operation
3.1 Extruder
Displays and operations are done on the "start" screen
3.1.1 Extruder drive

The adjustment of extruder speed is
done with the +/ - keys on the extra
keypad
The simultaneous adjustment of all
extruders, including the take-off
The state of readiness, speed [rpm] and

workload [%] for each extruder are
displayed.
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3.1.1.1 Alarms
The following alarms lead to a shutdown.
Emergency OFF Control voltage missing
10023 Extruder A, no pellets Monitored by a sensor in the feeder

10050 Extruder A, drive fault Fault in the drive's regulator. The regulator
will show a specific fault number
10053 Extruder A, pressure Melt pressure is too high
sensor 1 fault, melt
pressure
10204 Fault, no film Web break
12250 Extruder A, performance If an overload occurs while the extruder
limit reached. Automatic motor is accelerating, acceleration will be
mode was switched off stopped
3.1.1.2 Start conditions
The readiness to start is indicated by a green field
The following conditions must be fulfilled

The extra keypad's control voltage must be switched on
None of the aforementioned alarms may be pending

The temperature of the given extruder and die-head must
be reached
The melt pressure must not be too high
The drive regulator must be ready for activation
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3.1.2 Extruder melt pressure and temperature

Displays and operations are done on the "start" screen.
Each extruder can have up to 2 attached melt pressure transducers.
The melt temperature indicates the temperature of the
melt
The melt pressure shown is always the pressure just

before the screen pack.
Excessive melt pressure will produce an alarm and can
lead to a shutdown of the extruder.
The pressure difference shows the pressure drop across

the screen pack.
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3.1.2.1 Extruder melt pressure alarms
10051 Extruder A, pressure The transducer's output is a 4 to 20 mA

sensor 1, melt pressure current loop. When no current flows, this
transducer faulty alarm will be displayed
10052 Extruder A, pressure The preset alarm threshold has been
sensor 1, melt pressure exceeded
warning
10053 Extruder A, pressure The preset alarm threshold has been
sensor 1 fault, melt exceeded. The extruder will be shut down.
pressure
10054 Extruder A, difference The preset pressure difference is too great.
pressure too great The screen pack should be changed.
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3.1.3 Extruder grooved bushing heating/cooling unit

Displays and operations are done on the "heater" screen
Tempering units are operated from the "heater" screen.

The 3 fields are actual value [°C] [°F], setpoint [ °C] [°F] and regulation ratio [%].
Positive regulation ratios mean heating, negative ratios mean cooling. If the
deviation between setpoint and actual value is within the tolerance band, the
actual value display will have a green background. If the deviation is too large,
actual value will be displayed with a red background.
3.1.3.1 Extruder grooved bushing tempering unit alarms

10030 Extruder A tempering unit If the actual temperature is below the preset
too cold setpoint, a warning will be generated. The
limit is adjustable.
10031 Extruder A tempering unit If the actual temperature is above the preset
too hot setpoint, a warning will be generated. The
limit is adjustable.
10032 Extruder A tempering unit The tempering unit reports a fault. The
fault signal lamp on the tempering unit will
identify the fault.
3.1.4 Extruder edge trim return

Edge trim can be fed directly into the extruder. To keep displayed film thickness
correct, the running metre weight value will be corrected by the factor of fed edge
trim. The correction value is calculated from the difference between gross and net
widths.
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This function must be active on one extruder only. The status display indicates
whether edge trims are returned.
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3.2 Cooling ring and IBC blower

IBC stands for internal blower cooling; it is the term used for the supply and
exhaust blower used to regulate the exchange of internal air.
As many as 3 blowers may be present on a system.

• air ring blower
• supply blower
• exhaust blower
ON/OFF status display
speed setpoint [%]
speed actual value [%]
•
•
This can also be operated by way of the extra keypad.
The setpoint and actual value, as [%], are displayed for each blower. The
setpoint can be changed by making an entry via the extra keypad. Additionally,
the exhaust blower can be regulated via the USB controller.
Extra keypad
air ring blower
supply blower
air ring blower
The supply and exhaust blower can be driven

synchronously with the performance key
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3.2.1 Alarms
The following faults lead to a shutdown.
10040 Air supply fault Frequency inverter fault report
10041 Air exhaust fault Frequency inverter fault report
10042 Cooling ring fault Frequency inverter fault report
3.2.2 Start conditions

The extra keypad's control voltage must
be switched on
None of the aforementioned faults may

be pending
3.2.3 Cooling unit

Displays and operations are done on the "additives" screen.
Kirion makes it possible to operate 2 cooling units.
• Cooling ring temperature
• IBC supply air tempering
Temperature setpoint entry [°C / °F]
Temperature actual value display [°C /
°F]
3.2.4 Alarms
Detailed alarm indications are displayed directly on the cooling unit.
10043 Cooling unit, cooling ring Tempering unit's fault report;
fault this report is only enabled when the cooling
ring's setpoint is >50 %
10044 Cooling unit, supply air Tempering unit's fault report;
fault this report is only enabled when the cooling
ring's setpoint is >40 %
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3.3 USB
USB is an acronym for ultrasonic bubble control which provides non-contact
regulation for the bubble's diameter.
3.3.1 Functional principle

The bubble's distance from the calibration basket is the regulated factor. Distance
detection is done with 3 ultrasonic sensors on the calibration basket. The bubble's
distance from the basket is regulated by a throttle valve in the supply or exhaust
airflow. If regulation is switched off, the valve goes into its middle position.
Setpoint – and actual value display [mm] [in]

= bubble's distance from the basket
Regulator ON/OFF switch
Display of valve position
Important
The valve's position should not be in the red ranges. The valve's position
can be set by adjusting the IBC blower.
Extra keypad
switch USB ON/OFF
USB setpoint adjustment
3.3.2 Alarms
19035 PLC, USB motor, no data The positioning signal on the CAN bus is
over CAN bus missing.
19036 PLC, USB motor, check The PLC control module for the USB motor
PLC module is defective
19035 PLC, USB motor, wrong The wrong module has been inserted
data module
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3.4 Calibration basket

The height and diameter of the calibration basket can be adjusted manually.
Diameter is automatically adjusted when width regulation is active.
Extra keypad
manual height adjustment
manual diameter adjustment
3.4.1 Alarms
The following faults lead to a shutdown.
10201 Basket height fault The motor protection switch has triggered
10202 Basket diameter fault The motor protection switch has triggered
10205 USB coupling is defective No bus connection to the calibration
basket's local controller.
3.4.2 Calibration basket diameter display

In addition to the described manual adjustment, there is also an automatic
adjustment.
Setpoint and actual value display [mmdfl]
[indfl]
dfl = double web and lay width actual value
match
3.4.3 Calibration basket height display

In addition to the described manual adjustment, there is also an automatic
adjustment.
Setpoint and actual value display [mmdfl] [in]
dfl = double web and lay width actual value
match. The display also depends on the
operational mode.
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3.5 Bubble breakage monitoring

There is generally a sensor located above the calibration basket to monitor the
bubble. If this sensor does not detect film the entire system will be shut down.
Extra keypad
Bubble breakage monitoring will be started automatically
about 15 minutes after the system is started. The
monitor's "armed" status is indicated by the signal lamp.
The operator can use this control button to postpone
monitoring for another 15 minutes.
3.5.1 Web break monitor alarms

10203 Warning, no film Film is not detected. After a brief delay, the
plant will be shut down.
10204 Fault, no film Film is not detected. The plant has been
shut down.
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3.6 Width measurement

Displays and operations are done on the "start" or "controls" screen.
Setpoint and actual value display [mm]
[in]
Film thickness is calculated from the width setpoint value.
3.6.1 Width measurement alarms

Width measurement
14000 coupling interrupted no bus connection
Width measurement sled,
left: no measurement
14003 values
left: measurement value
14004 out of limits
14005 left: limit switch triggered
14006 left: test and EOS active
14007 left: cart does not move
14008 left: film sensor defective
14009 left: film too wide
14010 left: no film
left: no communication with
14011 width node
14012 reserved
right: no measurement
14013 values
right: measurement value
14014 out of limits
14015 right: limit switch triggered
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14016 right: test and EOS active
14017 right: cart does not move
14018 right: film sensor defective
14019 right: film too wide
14020 right: no film
right: no communication
14021 with width node
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3.7 Width regulation

Displays and operations are done on the "start" or "controls" screen.
Setpoint and actual value display [mm] [in]
3.7.1 Width regulation alarms

The difference between width setpoint and
actual value is too great.
The alarm threshold is adjusted in the
14001 Width out of limits "trend" screen.
Width regulator has been If basket diameter is adjusted manually,
14002 deactivated width regulation will be deactivated
Width regulation cannot be If net width <> gross width, width regulation
activated because will be deactivated
gusseting is active
14022
Net width too small When net width from order management is
14023 less than gross width by at least 120 mm.
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3.8 Take-off
Displays and operations are done on the "start" and "take-off" screens.
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3.8.1 Take-off drive

Setpoint and actual value display [m/min]
[ft/min]]
Open/closed status display for take-off
rollers
Extra keypad
take-off speed
slower / faster
take off roller, closed / open

status display
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3.8.1.1 Take-off alarms

15001 Motor protection switch in
take-off cabinet triggered
15002 Fault in one of the take-off Drive regulator fault
drives
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3.8.2 Take-off reversal

reversal on / off
reversal speed [%]
put reversal in start position
Take-off reversal angle [0° < 180°]
reversal time for 1 rotation [min]
3.8.2.1 Take-off reversal alarms

15001 Motor protection switch in

take-off cabinet triggered
15007 Take-off rotation tooth The rotation angle is determined by
count faulty counting teeth on the reversal gear. If the
count of teeth within a reversal of 360° is
too high or low, this alarm will be issued
3.8.3 Take-off turning bars

The turning bars can be rotated as a drive aid. The turning bars can be blocked. The
blocking of turning bars is switched on at a certain take-off speed (< 15m/min) or by
reversal outside of the start position.
Extra keypad
Block turning bars
LED status indicator
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3.8.4 Take-off turning bar blower

In order to prevent the film from skewing out of the middle during reversal, an air
cushion is created on the surface by 2 turning bars. This air cushion can be
influenced by way of 2 speed-regulated blowers. Furthermore, the air cushion can be
altered in response to turn angle; blower 1 is the upper, blower 2 the lower.
Setpoint for both blowers.
Each blower has one setpoint at an angle
of 180° and another at an angle of 0°
(360°).
During a reversal the setpoint changes
linearly in relationship with the actual turn
angle.
turning bar blower
100
90
blower setpoint [ % ]
80
70
60
50
40
30
20
10
0
0 90 180 270 360
angle [ ° ]
A graph of blower adjustment [%] in relationship to the turn angle [°].

In this example the blowers adjust from 30 % to 60 %.
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3.8.5 Take-off layflat display

Displays and operations are done on the "take-off" screen
Layflat display
[mmdfl] [indfl]
dfl = double web and lay
width actual value match
Extra keypad
Constrict / expand layflat angle
of collapsing frame
3.8.6 Take-off gusset up / down or side guide

Layflat display
[mmdfl] [indfl]
dfl = double web and lay
width actual value match
Extra keypad
Side guide top
narrower-wider
Side guide bottom

narrower-wider
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3.8.7 Take-off centering guide

Layflat display
[mmdfl] [indfl]
dfl = double web and lay width
actual value match
Extra keypad
Centering guide top
narrower wider
Centering guide bottom

narrower wider
3.8.8 Take-off auxiliary basket

Displays and operations are done on the "take-off" screen.
The auxiliary basket can be adjusted manually by way of the extra keypad or
adjusted automatically.
With automatic adjustment, positive values can increase contact with the bubble.
Negative values will reduce basket contact with the bubble. The basket responds
automatically to changes of lay width when regulation is activated.
When the start position is switched on, the basket opens up automatically.
Setpoint and actual value of bubble to

basket contact.
Start position: the basket opens up
completely
Extra keypad
manual operation of tube centring
guide (auxiliary basket)
open / closed
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3.8.8.1 Take-off auxiliary basket alarms

15020 Auxiliary basket: actual The basket's position to the film bubble is
value too small electrically measured with a mechanical
feeler arm. If the measured value is too
small, this alarm will be issued
15021 Auxiliary basket: actual The basket's position to the film bubble is
value too large electrically measured with a mechanical
feeler arm. If the measured value is too
large, this alarm will be issued
15022 Auxiliary basket: automatic When automatic mode is active the auxiliary
mode terminated by limit basket can move to its minimum or
switch. maximum diameter. When this happens,
automatic mode is deactivated.
3.8.9 Take-off heating/cooling unit

Displays and operations are done on the "take-off" screen.
This tempering of the take-off is done via roller tempering. Tempering can be
switched on and off.
Setpoint and actual value [°C / °F]
Switch roller tempering on/off
3.8.9.1 Take-off tempering unit alarms

15003 Take-off tempering unit too
cold
15004 Take-off tempering unit too
hot
15005 Take-off tempering unit Tempering unit fault report
fault
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3.8.10 Take-off intermediate take-offs

As many as 3 additional take-offs may be downstream of the actual take-off.
Switch drive on/off
Roller open/closed
Lead or lag motion [%]
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3.9 Dosing
The dosing unit measures extruder throughput and must mix the different materials
accordingly. Running metre weight is calculated from the throughput and take-off
speed. Film thickness is calculated from the width and specific weight.
In principle, only the extruders are regulated. The reference variable (master) is the
take-off.
The width setpoint and the material's specific density [g/cm³] are used to calculate
layer thickness.
The film's running metre is regulated. Throughput is not regulated.
Distinction is made between two methods of dosing; continuous dosing with dosing
screws, and charge (batch) dosing.
Continuous: Batch:
1 weighing cell per component 2 weighing cells
1 dosing motor per component 1 mixer motor
1 to 6 components are possible 4 or 6 components are possible
The two methods differ only in the manner the components are mixed. There is no
difference in extruder regulation.
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3.9.1 Extruder dosing regulation

Displays and operations are done on the "controls" and "dosage extruder x" screens.
Individual layer thicknesses [µm / mil]

Individual layer thicknesses [%]
Total layer thickness [µm / mil]
Metre weight [g/m / lbs/kft]]
The sum of layer thickness distribution must

always be 100 %. A correct entry is indicated
by a green dot.
New setpoints will only be accepted for a

correct setpoint entry.
The display can be switched between %

distribution and running metre weight.
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Automatic layer thickness regulation can be

switched on and off. If regulation is switched
on, the speed of extruders is adjusted
automatically.
3.9.1.1 Extruder dosing intended throughput

Displays and operations are done on the "controls" and "dosage" screens.
Entry of an intended throughput and
activation of this function will cause a one-
time adaptation of extruders and the take-off
to these new values.
This function is enabled on extruders

individually; the enable is done on the
"dosage extruder x" screen.
The throughput for all extruders can be
adjusted manually. This does not change
layer density and the ratio of layers.
3.9.2 Material pre-selection

The specific weight [g/ccm³] of components is an important factor for the layer
thickness calculation. A feature which allows the material to be selected directly from
a database simplifies this entry.
Material pre-selection can be done on the "dosage extruder x" screen or on the
"dosage material" screen.
in the "dosage extruder x" screen
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in the "dosage material" screen
Use the following procedure for material pre-selection:

• select components (e.g. extruder B, beside 1)
• press Enter
• Select material (for rapid indexing, the name can also be entered via keyboard)
Each data record contains the following information:

name Unique name for identification
this name can only be used once
density Material density
necessary for calculating film thickness
type free sorting field
manufacturer Manufacturer's name or acronym
bulk density bulk weight
necessary for the "residual quantities management"
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function
ID material's identification number
This entry can be assigned freely.
class classification
This entry can be assigned freely.
MFI melt flow index
V-temp processing temperature
A-temp fusing temperature
anti-block portion of anti-block
slip portion of slip
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3.9.3 Continuous dosing

Displays and operations are done on the "controls" and "dosage" screens.
The desired portion can be set for each
component.
The main component's portion is simply the
remainder to be apportioned.
There are three possible modes for every

component:
1: OFF
2: Man
Throughput regulation for the component is
deactivated. The dosing worm rotates at a preset
speed. Once this speed is set, it will adjust
synchronously with the extruder. This mode of
operation is called "volumetric".
3: Auto
Throughput regulation for the component is
activated.
This mode of operation is called "gravimetric".
The green dot symbolises correct functionality for

the main component.
A violet dot symbolises suspended regulation.
A red dot symbolises a fault or warning.
Corresponding symbols apply to the actual value
display of the respective component.
• The sum of auxiliary components should be less than 70 %.

• The setpoint for any one auxiliary component should be less than 50 %.
• The doser screw should be utilised according to its throughput.
• The minimum throughput with active regulation is about 1 kg/h.
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The "dosage extruder A" screen provides a detailed overview of the extruder.
Aside from the described entries for running metre weight or percentage distribution,
there are other necessary entries and important displays.
3.9.3.1 Continuous dosing feed rates and speed controls

extruder speed [rpm]
extruder screw feed
rate [kg/rpm / lbs/rev]
setpoint and actual

value for dosing speed
[rpm]
actual feed rate of the
dosing screw [kg/rpm]
dosing operational
mode [see above]
After entering dosing speed this value resets to 0. The dosing unit then runs
synchronously with the extruder.
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3.9.3.2 Continuous dosing material pre-selection

Specific density is necessary to
calculate material thickness. Material
density is stored in the material
database to simplify entries.
The top field displays composite

material density for all components.
100 %
density=
maincompon (%) compon 1 (%)... compon x (%)
+ + ..
density maincompon ( g / ccm) density compon. 1 ( g / ccm) densitycompon. x ( g / ccm)
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3.9.3.3 Dosing screws

The list below provides an overview of the dosing screws used. The primary factor in
selecting a dosing screw is its throughput.
P1 RCM2
Standard Option
Motor type: DC motor servo motor

Output power: 125 W 200 W
Motor speed: 4000 rpm 4000 rpm
Gearing ratio: 25 : 1 10 : 1
Worm: 3 ... 157 U/min 0.4 ... 400 U/min
Torque: 8 Nm 11 Nm
Speed range: 1 : 52 1 : 1000
Feed rate: Dosing range (kg/h) Dosing range (kg/h)

yellow
0.3* - 2.2 -
0.015
brown
0.3* - 7.5 -
0.05
red
0.7 - 18 0.3* - 40
0.12
green
3 - 67 1 - 135
0.45
green/
black 5 - 120 1.5 - 250
0.8
black
9 - 225 1.5 - 500
1.5
* 0.3 kg/h only in volumetric dosing mode
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3.9.3.4 Continuous dosing alarms

12000 Extruder A, main component Weigher cell: weight outside valid
weigher measurement out of measurement range.
limits Weigher cell: defective or incorrectly
attached, check supply voltage
12001 Extruder A, main component Speed: signal outside valid measurement
speed measurement out of range.
limits Speed: sensor defective, check supply
voltage.
12002 Extruder A, main component Weighing hopper could not be filled in the
hopper fill-time expired prescribed time.
Material deficiency in the supply container.
Check suction conveyor, check supply air
to slide valve.
Check slide function by using the manual
open/close switch.
Check material fill level in the hopper, the
use of materials having strongly varying
bulk density can cause over-filling.
12003 Extruder A, main component Suction feeding insufficient.
hopper empty Slide valve does not open.
Put the Man / Auto switch on PC5K in
manual position.
Compressed air pressure too low.
No valid weighing signal.
12004 Extruder A, main component The service switch on PC5K is not in the
hopper switch not in Auto "AUTO" position.
Automatic filling of the weighing hopper is
not possible.
Weighing hopper can run empty.
12005 Extruder A, main component Weighing hopper is almost empty.
throughput measurement Material deficiency in the supply container.
invalid Screw speed acquisition is instable.
12006 Extruder A, main component The edge strip extruder was switched off
throughput measurement, during production.
edge strips torn off Edge trim calculations are suspended.
Extruder regulation switches off.
12007 Extruder A, main component Material deficiency in the weighing hopper.
throughput regulation, no Throughput measurement no longer
valid values possible. Screw speed instable.
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12008 Extruder A, main component Speed was manually adjusted during

throughput regulation, automatic mode.
deviation too large Check speed acquisition (speed pulse
generator, cable, etc).
12009 Extruder A, main component The extruder was switched off during
throughput regulation, regulated operation.
extruder switched off Emergency OFF chain was activated.
Film break.
The digital input signal "Extruder ON" was
deactivated.
All slide valves remain closed, all
measuring and regulating functions are
suspended.
12010 Extruder A, main component Motor run up to maximum speed.
throughput regulation, Check production data, reduce machine
setpoint not reached performance if necessary.
12011 Extruder A, main component Setpoint/actual value deviation is greater
speed regulation, regulation than 10 percent.
out of tolerance Conversion time expired.
Extruder throughput instable, see pressure
or flow display.
Throughput measurement values instable.
Weighing aggregate must be checked.
Compressed air pressure for the slide valve
too low.
Material fill level in the hopper too high.
Faulty cable connections.
12012 Extruder A, main component Speed measurement value was underrun
speed regulation, or overrun.
measurement value out of Check speed acquisition (speed pulse
limits generator, cable, etc).
12013
12014
12015 Extruder A, main component At least one setpoint is recognised as
invalid setpoints for product invalid following a setpoint change.
conversion Check setpoint changes, perhaps a
decimal point position mistake was made
12016 Extruder A, main component
measurement instable
Weigher cell: weight outside valid

Extruder A, auxiliary measurement range.
component x, weigher Weigher cell: defective or incorrectly
12100 measurement out of limits attached, check supply voltage
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Speed: signal outside valid measurement

Extruder A, auxiliary range.
component x, speed Speed: sensor defective, check supply
12101 measurement out of limits voltage.
Weighing hopper could not be filled in the
prescribed time.
Check suction conveyor, check supply air
to slide valve.
open/close switch.
Extruder A, auxiliary Check material fill level in the hopper, the
component x, hopper fill-time use of materials having strongly varying
12102 expired bulk density can cause over-filling.
Not enough suction conveyor power.
Slide valve does not open.
The Man / Auto switch on PC5K is in
manual position.
Extruder A, auxiliary Compressed air pressure too low.
12103 component x, hopper empty No valid weighing signal.
The service switch on PC5K is not in the
"AUTO" position.
Extruder A, auxiliary Automatic filling of the weighing hopper is
component x, hopper switch not possible.
12104 not in Auto Weighing hopper can run empty.
Extruder A, auxiliary Weighing hopper is almost empty.
component x, throughput Material deficiency in the supply container.
12105 measurement invalid Screw speed acquisition is instable.
Extruder A, auxiliary The edge strip extruder was switched off
component x, throughput during production.
measurement, edge strips Edge trim calculations are suspended.
12106 torn off Extruder regulation switches off.
Material deficiency in the weighing hopper.
Extruder A, auxiliary Throughput measurement no longer
component x, throughput possible.
12107 regulation, no valid values Screw speed instable.
Extruder A, auxiliary Speed was manually adjusted during
component x, throughput automatic mode.
12108 regulation, deviation too large Check speed acquisition
The extruder was switched off during
regulated operation.
Extruder A, auxiliary Emergency OFF chain was activated.
component x, throughput Film break.
regulation, extruder switched The digital input signal "Extruder ON" was
12109 off deactivated.
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All slide valves remain closed, all

measuring and regulating functions are
suspended.
Extruder A, auxiliary Motor run up to maximum speed.
component x, throughput Check production data, reduce machine
regulation, setpoint not performance if necessary
12110 reached
Setpoint/actual value deviation is greater
than 10 percent.
Conversion time expired.
Extruder throughput instable, see pressure
or flow display.
Extruder A, auxiliary Compressed air pressure for the slide valve
component x, speed too low.
regulation, regulation out of Material fill level in the hopper too high.
12111 tolerance Faulty cable connections.
Extruder A, auxiliary Speed measurement value was underrun
component x, speed or overrun.
regulation, measurement Check speed acquisition (speed pulse
12112 value out of limits generator, cable, etc).
The internally calculated setpoint for
Extruder A, auxiliary regulation (e.g. dosing tracking) for a
component x, speed deactivated conversion lies outside the
regulation, setpoint out of valid range.
12113 limits Change the dosing screw.
The motor's electronic overload protection
has triggered.
Check for a material jam.
Extruder A, auxiliary Dosing screw feed capacity exceeded.
component x, speed Problematic material properties, a larger
regulation, motor overloaded: cylinder may be necessary.
12114 wrong worm Check the dosing motor's carbon brushes
At least one setpoint is recognised as
Extruder A, auxiliary invalid following a setpoint change.
component x, invalid setpoints Check setpoint changes, perhaps a
12115 for product conversion decimal point position mistake was made.
Extruder A, auxiliary
component x, measurement
12116 instable
The plant was shut down due to a
component's material deficiency. See
12255 Plant stop setting on service screen "plant stop".
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3.9.4 Charge dosing (batch)

Displays and operations are done on the "controls" and "dosage" screens. The
system consists of 2 containers fitted with one weigher.
The individual components are dosed out one after the other into the upper container
(batch).
Once the mixture is complete, it is allowed to fall into the lower container (mixer). The
weight loss from this container is the throughput for the given extruder.
The desired portion can be set for each
component [%].
The portion of the first component is simply the
remainder to be apportioned.
There are two possible modes for every
component:
1: OFF
2: ON
The setpoint [%] of a component should be appropriate for the supply hopper.
The standard layout is as follows:

4 components:
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component 1 2 3 4
setpoint 10-100% 10-100% 1-20% 0.5 -10%
6 components
component 1 2 3 4 5 6
setpoint 10-100% 10-100% 10-100% 1-20% 1-20% 0.5 -10%
3.9.4.1 Charge dosing feed rates and speed controls

extruder regulation [off/on]
intended throughput [off/on]
extruder speed [rpm]
extruder worm feed rate [kg/rpm /
lbs/rev]
running metre weight, setpoint and

actual value [g/m / lbs/kft]
throughput [kg/h / lbs/h]
3.9.4.2 Charge dosing material pre-selection and handling

Specific density is necessary to
calculate material thickness. To
simplify entry, material density is
stored in a database.
The tolerance entry depends on the volume to be dosed. An alarm will be generated
as soon as the deviation between setpoint and actual value becomes greater than
this tolerance.
Dosing can be switched on or off.
The valve / flap between the
supply container and the batch
hopper is normally operated
automatically. If the components
are switched off, the valve
remains closed (><). This valve
can be opened for cleaning
purposes (> <).
The valve for a component can be opened manually at any time. Material
mixtures resulting from such an action can damage the extruder.
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Density display for the mixed materials.
The weight of the active batch will be

displayed.
The batch container's flap is normally
operated automatically but can also be
manually closed or opened.
Density is calculated with the following equation

100 %
density=
compon 1 (%) compon 2 (%)... compon x (%)
+ + ..
density compon 1 ( g / ccm) density compon 2 ( g / ccm) density compon x ( g / ccm)
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3.9.4.3 Charge dosing mixer

mixer weight display [kg / lbs]
valve open/closed/auto (slide
valve between extruder and
batch system (option)
Mixer motor [off / on / auto)
Dosing [off / on], this is a switch
which permits access to local
dosing setpoints. This switch
should always be in automatic
mode when operating via Kirion
C.
3.9.4.4 Charge dosing alarms

12500 Batch extruder A, alarms Alarms will be registered by the system but the
DEACTIVATED acoustic or visual indicator at the machine will
not be activated. Switching alarms on and off
is done by the operator with a respective
control button on the alarm screen.
12501 Batch extruder A, no backup This alarm notifies the operator that the system
data has started and is loading the data that was
stored the last time the STORE TO ROM
control button was activated. This display
terminates when alarms are reset. If this alarm
occurs, the proper functionality of the program
must be checked and the manufacturer's
customer service department notified.
12502 Batch extruder A, external This indication is analogous to a previous one
TIMEOUT remote I/O CP 430 but is in relationship to the external GEC
control module which controls the take-off and
extruder (if this controller is configured into the
system).
12503 Batch extruder A, external This is a display arising from missing CAN
TIMEOUT remote I/O X67#1 communication between the PLC and I/O
control modules responsible for feeding the
dosing unit.
dosing unit.
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dosing unit.
dosing unit.
dosing unit.
dosing unit.
12509 Batch extruder A, MIN fill The dosing unit's minimum fill level sensor is
level, dosing unit #1 exposed at the surface. Check if the pellet
sucker is properly delivering material to the
dosing unit.
dosing unit.
dosing unit.
dosing unit.
dosing unit.
dosing unit.
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12515 Batch extruder A, dosing unit The dosing unit's actual value lies outside the
#1 OUTSIDE tolerance range preset tolerance band. Possible causes are:
pellets have blocked the slide valve, water or
dirt in the pneumatic line, no material available,
compressed air outage, defective magnet
valve, problems with the cylinder.
12521 Batch extruder A, component Material is not available in the dosing unit's
#1 missing hopper, the hopper is clogged, or there is not
enough material at this slide valve to uphold
the intended throughput.
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12527 Batch extruder A, irregular This alarm is generated frequently in transition
flow in dosing unit #1 phases and is caused by a changeover to
material with a different pourability. During
normal processing this alarm indicates uneven
material dosing, typically caused either by lack
of material or by material with bad pourability.
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12533 Batch extruder A, dosing unit A material flow has developed that deviates
#1, NOT OK too much from the intended flow. When this
alarm occurs during normal processing it
indicates potential problems with the slide
valve. Possible causes are: pellets have
blocked the slide valve, water or dirt in the
pneumatic line, no material available,
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valve, problems with the pneumatic line.
12539 Batch extruder A, trim hopper Material in the trim hopper has reached its
full highest - minimum fill level.
12540 Batch extruder A, trim hopper Material in the trim hopper has reached its
empty highest - minimum fill level.
12541 Batch extruder A, mixer cover
open
12542 Batch extruder A, mixer MIN Material in the mixing hopper has reached the
fill level value set with the parameter MIXER MINIMUM
FILL LEVEL (kg). A check must be made to
see: if the dosing system is on RUN, if material
is lacking in the dosing unit's hoppers, and if
the dosing cycle is perhaps too long; in this
last case, extrusion throughput must be
reduced or a check made to see if the %
setpoints for dosing are too high.
12543 Batch extruder A, mixer The mixer motor is locked out due to
thermal protection overheating.
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12544 Batch extruder A, mixer not The mixer did not fill itself after the batch
filled hopper was emptied. Check if the batch
hopper's slide valve has opened properly and if
material is missing in the hoppers.
12545 Batch extruder A, batch The weight of the weigher hopper has reached
weigher full the kg value preset in the parameter
MAXIMUM BATCH WEIGHT (kg). This alarm
is typical of problems with the pneumatic lines
(water present, pressure fluctuations) or for
mechanical problems (pellets that slow down
the slide valve). If no problems are present,
one can increase the value of the
aforementioned parameter.
12546 Batch extruder A, batch The batch discharge valve did not open within
weigher NOT empty the BATCH DISCHARGE TIMEOUT (S)
period. The cause of this alarm is either
inaccurate calibration of weigher cells, an
excessively large batch with discharge level
set too high, or a mechanical or pneumatic
problem at the batch weigher (piston, slide
valve, etc).
12547 Batch extruder A, weigher The hopper's slide valve did not close again
open, dosing cannot take after discharging the batch hopper. The cause
place of this alarm is either inaccurate calibration of
weigher cells, an excessively large batch with
discharge level set too high, or a mechanical
or pneumatic problem at the batch weigher
(piston, slide valve, etc).
12548 Batch extruder A, weigher The alarm "weigher closed, mixer not filled" will
closed, mixer not filled be issued when at least one dosing unit has
the status OPERATING, the weigher has the
status CLOSED and global status RUN is true.
If the operator resets this alarm, but the alarm
condition persists, then the alarm will be
issued again after the blanking period expires.
In this case, the machine will perform dosing
but the mixer will not fill even though it has a
command signal.
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12549 Batch extruder A, dosing unit The alarm "dosing unit STOP at SW% dosing
#1 STOP at SW% dosing > 0 > 0" will be issued for any dosing unit with
status STOP, a dosing percentage >0 and the
GLOBAL RUN status. If the operator resets
this alarm, but the alarm condition persists,
then the alarm will be issued again after the
blanking period expires. In this situation the
machine switches dosing tolerance control off.
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12555 Batch extruder A, dosing unit
#1 STOP with OPEN valve
12561 Batch extruder A, flow control
valve CLOSED
12562 Batch extruder A, mixer The material fill level lies under the mixer
hopper MIN fill level hopper's minimum fill level sensor.
12563 Batch extruder A, throughput Indicates the worm mounted on the extruder is
NOT realised not capable of feeding demanded throughput
or the dosing unit mounted on the extruder
cannot handle the preset percentages
demanded for throughput.
12564 Batch extruder A, extruder The extruder's ACTUAL % value in kg/h is
throughput OUTSIDE outside the tolerance band. Check to see if
tolerance range pellet feeding is operating properly, if there are
mechanical obstacles on the weigher cells, if
the filter is clogged or if the feeding of trim is
irregular.
12565 Batch extruder A, reduced The extruder is running faster than intended to
throughput / excessive keep up with the preset throughput. Check for
extruder speed possible filter clogging.
12566 Batch extruder A, trim The trim has torn off. (A parameter is only
breakage present if the system is set up to control further
usage of trim in the line.) Check to see why the
customer-supplied contact on the dosing unit is
open (trim breakage, cable pulled off, etc).
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12567 Batch extruder A, take-off The ACTUAL % value for take-off speed lies
speed OUTSIDE tolerance outside the preset tolerance band. This alarm
range is generated when, despite a command sent
out, take-off speed does not change
accordingly. The problem is usually to be
found in the take-off's control unit.
12568 Batch extruder A, thickness / The ACTUAL % value g/m lies outside the
metre weight OUTSIDE preset tolerance band. This alarm typically
tolerance range occurs at a sudden change of throughput, i.e.
in conjunction with the alarm "Extruder out of
Tol.", or when a change of line speed takes
place due to mechanical or electrical take-off
problems.
12569 Batch extruder A, Emergency Locks up the entire plant, triggered by an
OFF button activated activated Emergency OFF button. The
Emergency OFF function is only activated
when a connection is made to the provided
terminal board in the electrical switchgear box.
12570 Batch extruder A, lot end (kg) In the console's ORDER screen there is a
parameter for "Order quantity" in which the
total quantity to be produced is established.
When counter 1 exceeds this preset value, this
alarm will be issued. The alarm will occur
again after it has been reset if the situation
continues to be true. This control is disabled
when the parameter value is preset to zero.
12571 Batch extruder A, suction Pump motor locked out due to overheating.
pump thermal protection This overheat condition can be caused by a
clogged suction filter or discharge filter (which
are to be cleaned at regular intervals), by
material clogging the suction line or by a
problem with the suction pump.
12572 Batch extruder A, dosing unit Pneumatic feeding of station no. # has
#1 feed blocked exceeded the preset time. The possible
causes are: filter clogging in the receiving
container, clogged line, no material in the
supply hopper from which supplies are being
taken, losses in the lines. If this alarm occurs
despite sufficient feeding of material into the
system, the operator can increase the
maximum allocated time by 10 ... 20 % (see
configuration).
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configuration).
configuration).
configuration).
configuration).
60 / 215
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configuration).
12578 Batch extruder A, weigher cell Indicates that the calibration procedure for the
(weigher) not calibrated dosing controller's weigher was not concluded.
This problem occurs when the cell does not
detect any significant difference between
calibration at empty and sample weight
(distance between "raw values" < 250 000).
12579 Batch extruder A, weigher cell Indicates the calibration procedure for the
(mixer) not calibrated mixer was not concluded. This problem occurs
when the cell does not detect any significant
difference between calibration at empty and
sample weight (distance between "raw values"
< 250 000).
12580 Batch extruder A, PLC Indicates there are communication problems

TIMEOUT, layer A between PLCs; in particular (M#A: PLC
timeout PLC layer #C) indicates the PLC which
controls layer A has communication problems
with layer #C. Therefore the reference value of
the PLC with a communications blockage is
not to be sought at the extruder specified by
the coded description (M#A) but rather at the
one specified in the alarm's description line.
TIMEOUT, layer B between PLCs; in particular (M#A: PLC
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TIMEOUT, layer C between PLCs; in particular (M#A: PLC
TIMEOUT, layer D between PLCs; in particular (M#A: PLC
TIMEOUT, layer E between PLCs; in particular (M#A: PLC
TIMEOUT, layer F between PLCs; in particular (M#A: PLC
TIMEOUT, layer G between PLCs; in particular (M#A: PLC
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TIMEOUT, layer H between PLCs; in particular (M#A: PLC
TIMEOUT, layer I between PLCs; in particular (M#A: PLC
12589 Batch extruder A, I/O Indicates there are communication problems
initialisation not OK between PLCs; in particular (M#A: PLC
12590 Batch extruder A, hardware
key not OK
19021 Extruder A, PLC gravimetric
CAN coupling disrupted
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3.10 Winder
This "Winder" section applies to the WS winder as well as the WM winder.
The essential differences between these two winder types are the differing operator
panels and different scope of functionality. Nevertheless, their operation on Kirion C
is identical.
3.10.1 WM winder
The WM winder has its own IPC. The extruder can also be operated from this display
panel. The only difference in comparison to the extruder's panel are the function keys
in the 2nd row.
Pressing the primary nip's start button will cause a 4 second long pulsing siren tone.
Afterwards, the selected plant section starts up.
Switching off the primary nip also switches the winder off.
Winders can be switched "on" and "off" independently of one another but the primary
nip must be switched on beforehand.
To catch up a loose web upstream of the winding station, press and hold the ACC
button for the given drive to catch up until the web has been reached. This function
increases the preset winding speed.
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The alarm dialogue window can be called up directly with the software "Alarm"
button.
3.10.2 WS winder
Operations are performed with the PP41 panel.
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3.10.3 Winder overview

The "winder overview" screen can be called up from the "overview" screen with the
function key
"WINDER"
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The following abbreviations will are used:

Intermediate Station
IS
intermediate take-off
Primary Nip
PN
pre-take-off
Cooling
CW
cooling roller train
Trim Control
TC
trim take-off
Spreader WD
STC
spreader cooling roller train
Spreader WD
SWD
spreader winder drum
Winder Drum
WD
winder drum
Central Drive
CD
central drive
Constant Lay On Pressure
CLP
winder lay-on pressure
3.10.3.1 Winder metre counter

The images on this screen show actual metre count, the remaining metre count for
the current roll as well as the winding time remaining (in minutes) until the next cut for
both winders is displayed simultaneously.
In automatic mode, web separation takes place when the preset metres count has
been reached.
The control buttons can be used to jump to other dialogue windows for the given
winder.
This entry field is used to specify the length [m / ft] for the
next roll. This preset value will be put into the CURRENT
ROLL length setpoint field when the cutting process is
performed. This preset value remains the same until it is
changed by the operator.
A cutting process will cause the value NEXT ROLL length
setpoint to be placed into this entry field. The length of the
current roll can be changed (e.g. lengthened due to defect
sections) anytime before the automatic roll change process
is initiated. After the cutting process, the NEXT ROLL
length setpoint value will again be placed here.
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Remaining length (in metres) to the next cut process
Remaining winding time, in minutes, until the next roll

change
Length of the last wound roll
Displays the number of roll records (since last manual

reset). The number of cutting processes are counted to
produce this number.
Display of overall length [m /ft] since the last manual reset.

Displays the total length of all finished rolls plus the length
of the current roll.
Switch metre counter on / off
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3.10.4 Winder drives and settings
3.10.4.1 Winder's intermediate take-off drive (IS)
Switch drive on / off
The drive turns only after the primary nip

[PN] is switched on.
open / close pressure roller
tension setpoint [N / ft/klbs]
tension actual value [N / ft/klbs]
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3.10.4.2 Winder's primary nip drive PN

winder IPC function buttons:
switch drive on / off
start screen function buttons


3.10.4.3 Winder's cooling roller train drive CW

The cooling roller train starts automatically with the winder station.
3.10.4.4 Winder's trim nip drive TC

The trim nip starts automatically with the winder station.
slowdown for negative values

speedup for positive values
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3.10.4.5 Winder's spreader cooling roller train drive STC

This drive starts automatically with the winder station.

3.10.4.6 Winder's spreader drive SWD

This drive starts automatically with the winder station.

3.10.4.7 Winder's winding station drive WD

The primary nip must be running before this drive is switched on.
winder IPC function buttons:

drive acceleration on / off

3.10.4.8 Winder's central drive CD

Switch drive on / off
The drive turns only after the primary nip
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[PN] is switched on.
3.10.5 Winder operational modes

The different types of winding are set in this screen, and explained individually in this
section.
Both central drive mode and CLP mode permit various levels of tension to be set in
relationship to winding diameter.
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0
0 10 20 30 40 50 60 70 80 90 100
-20
Taper curve
-40
Taper in %
-60
-80
-100
-120
Rolldiameter in %
150
CLP curve
100
pressure change in %
50
0
0 10 20 30 40 50 60 70 80 90 100
-50
-100
-150
Rolldiameter in %
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3.10.5.1 Winder contact winding mode
The roll lies only with its own weight on the winding roller; a variable pressure of
about 400 ... 900 N. This type of winding is the easiest to set up. It is only necessary
to pre-select winding tension.
3.10.5.2 Winder contact angle mode + CLP

CLP (Constant Layon Pressure) is a means of achieving consistent layon force for
the roll being formed against the driven winder roller. The layon pressure, between
100 and 4000 N, is pre-selected with a manometer and will be displayed as an
analogue value. The CLP system can be switched on or off for every mode of
operation. If CLP is switched off, the winder operates as a pure contact winder, i.e.
the roll's own weight produces a natural, variable layon pressure of about 400 ... 900
N while the roll is being formed.
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Contact winding combined with CLP produces a constant layon pressure that can be
pre-selected within a range of 100 ... 1000 N. This mode of winding results in better
roll quality than does pure contact winding. Roll hardness can be adjusted better. The
pre-selected layon pressure must be greater than 100 N.
3.10.5.3 Winder contact angle mode + CLP + central drive mode
This mode is used primarily for lustreless, pressure-sensitive material that can be
gently wound with a light layon pressure of about 100 ... 1000 N. Roll telescoping can
be prevented by using pre-selected tension depreciation.
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3.10.5.4 Winder gap winding mode
GAP
Gap winding is performed without contact to the winder roller. The roll being formed
is continuously calculated such that a specified distance from the winder roller can be
maintained. Gap winding can only be accomplished with central drive and CLP
switched off.
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3.10.6 Winder diagrams

This screen provides an overview of speeds [m/min / ft/min] and corresponding
tension values as bar graphs [N / ft/lbs].
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3.10.7 Winder accessories

The winder can be equipped with various optional features. These can be switched
on or off here.
These optional units switch on/off along with the respective winder, provided the
given modules have also been activated in winder settings.
In an activated mode, the options rotary winder support legs, shaft support and
winding direction remain switched on regardless of the winder's on/off operational
state.
3.10.7.1 Winder vacuum pump

VACUUM Drum vacuum is switched on and off by
way of the ON/OFF button.
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3.10.7.2 Winder traverse and longitudinal oscillation

TRANSVERSE All LS installed in the winder station can
OSCILLATION be altered sideways by 0 ... 4 mm with the
ON/OFF control field. Depending on the
eccentric in place, other values can also
be achieved. This type of oscillation
should be switched on for film types
which have a tendency to form an edge
when being cut.
LONGITUDINAL Longitudinal oscillation is switched on and
OSCILLATION off by way of the ON/OFF button. This
moves the cutting edge of the knife in the
film by ± 2 mm, i.e. the knife will have a
longer service life.
LATERAL OSCILLATIONS All LS installed in the primary nip can be
IN PRIMARY NIP altered sideways by 0 ... 4 mm with the
ON/OFF control field. Depending on the
eccentric in place, other values can also
be achieved. This type of oscillation
should be switched on for film types
which have a tendency to form an edge
when being cut.
PRIMARY NIP Longitudinal oscillation is switched on and
LONGITUDINAL off by way of the ON/OFF button. This
OSCILLATION moves the cutting edge of the knife in the
film by ± 2 mm, i.e. the knife will have a
longer service life.
3.10.7.3 Winder trim-strip vacuum

TRIM REMOVAL PER Winder-individual trim-strip removal is
WINDER switched on or off by way of their
respective ON/OFF buttons.
TRIM REMOVAL Primary nip trim-strip removal is switched

PRIMARY NIP on or off by way of the ON/OFF button.
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3.10.7.4 Winder roller cooling

PRIMARY NIP ROLLER Cooling is switched on and off by way of
COOLING the ON/OFF button.
ROLLER COOLING Cooling is switched on and off by way of

INTERM. TAKE-OFF the ON/OFF button.
ROLLER COOLING Cooling is switched on and off by way of

COOLING DRUM the ON/OFF button.
3.10.7.5 Rotary winder support legs

ROTARY WINDER The default time is 15 s. The raising and
SUPPORT LEGS lowering of supports is only possible in
the winder's final position. The
prerequisite for this is that there is no
shaft in the load arm.
Reset mode always enables raising.
3.10.7.6 Winder shaft supports

SHAFT SUPPORT ON This option's shaft supports, which are
LOAD ARM located on the winder, are activated here.
3.10.7.7 Winder winding direction

WINDING DIRECTION Activating this button changes the
direction of the winding drum's rotation.
TOP = film drawn in at top
BOT = film direction downward,
drawn in between the cutter rollers.
The switchover can be done only while
the machine is at a standstill and it will
take about 5 s.
If an alarm indicates that direction
reversal was not correctly carried out on a
drive, the alarm must be acknowledged
and the rotation reversal selected again!
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3.10.7.8 Winder tempering units

The Extras button provides access to roller temperature settings.
If the winder has no tempering units for possible cooling rollers, neither the
aforementioned "Temp" button nor the dialogue window described here will be
present.
STATE Tempering units are switched on and off

by way of their respective ON/OFF
buttons.
ACTUAL °C Shows the current temperature in the
circuit.
SET °C The desired circuit temperature can be
entered here.
REGUL. RATIO % Shows the regulation ratio in percentage.
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Winder roll change

A roll change can be initiated automatically via metre counter or with the [ ] button
on the keypad for the given winder. Ensure a winder shaft with core and tape is
present in the pick-up position before initiating this operation. If the "Hand"
pushbutton is activated, a manual roll change will be initiated in which each
pushbutton is to be activated in the arranged sequence.
3.10.7.9 Winder status display

The winder status screen shows if a winder is ready for a roll change. The display is
set up like a traffic light.
Red display = module is not ready for a roll change! Its condition must be rectified.
Green display = module is ready.
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3.10.8 Winder fault messages

The maximum roll diameter has been
exceeded in the pre-winding station. The
5 winder will be turned off for reasons of
Winder %1, maximum roll safety.
diameter attained in the pivot Determine why roll change is taking longer
arm. than permissible roll growth in the pre-
11000 winding station.
There is no shaft inserted in the magazine.
The roll diameter has reached a critical
Winder %1, magazine load value. If roll diameter increases further, a
11001 shaft timeout shaft cannot be inserted.
The roll diameter has reached a critical
Winder %1, roll change: no value. If roll diameter increases further, a
11002 shaft in the magazine shaft cannot be inserted.
Winder %1, roll change: The deposit location (pallet, roll cart, ...)
11003 deposit location not ready does not return a ready (free) signal.
The roll's diameter has exceeded its
maximum value.
Every winder is designed for a particular roll
diameter. Once this diameter is reached, a
Winder %1, roll diameter roll change will be initiated (automatic mode)
greater than maximum or requested (manual mode). If this is not
11004 diameter. possible, the winder will be halted.
Winder %1, shaft magazine
11005 motor protection switch The motor is overloaded or blocked.
Winder %1, shaft did not
11006 arrive in transfer position The limit switch was not activated.
Winder %1, shaft magazine The shaft positioner was not in its base
11007 not in base position position when the roll change started.
Winder %1, winder direction
11008 reversal could not be activated nn
The shaft positioner moved beyond the
initiator for the transfer position. The roll
Winder %1, shaft positioner change function cannot be accomplished
11009 moved too far reliably.
Winder %1, pivot arm forward
Winder %1, pivot arm
backward motor protection
11011 switch The motor is overloaded or blocked.
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The crosscut knife was not in its base

Winder %1, knife not in base position when the roll change started.Check
11012 position the proximity switch.
Winder %1, shaft accelerator
Winder %1, shaft accelerator The shaft accelerator is not in its base
11014 not retracted position.
Winder %1, lift crane motor
11015 protection switch The motor is overloaded or blocked.
Winder %1, deposit location The deposit location is currently in use by the
11016 not free other winder.
Winder %1, knife bar not in The knife bar was not in its base position
11017 base position when the roll change started.
Winder %1, pivot arm not in The pivot arm was not in its base position
Winder %1, slitting roller in
wrong position (rotation
11019 reversal) The limit switch was not activated.
Winder %1, hydraulic pump
motor protection switch / fault The motor is overloaded, blocked or there is
11020 in frequency inverter a fault in the frequency inverter.
Winder %1, hydraulic oil The hydraulic oil is too hot. Please check the
11021 overtemperature oil level and observe the warning notice.
Winder %1, load arm: fault The correct values could not be transferred
11022 during parameter transfer to the frequency inverter.
Winder %1, invalid command
11023 code software program error
11024 Winder %1, safety bumper The safety bumper was activated.
Winder %1, safety zone
11025 overrun The floor mat was activated.
The load arm's angle transducer provides no
11026 Winder %1, encoder fault valid values.
Winder %1, load arm: Em. An Emergency OFF switch or Emergency
11027 stop activated OFF pull-cord has been activated.
Winder %1, oil pressure too
11028 low The hydraulic pressure is too low.
Winder %1, left load arm not The left load arm is blocked or the limit
11029 extended to the right switch was not activated.
11030 extended to the left switch was not activated.
11031 retracted to the right switch was not activated.
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11032 retracted to the left switch was not activated.
Winder %1, rotary winder not The rotary winder is not in the correct
11033 in position position or the limit switch was not activated.
Winder %1, winder shaft The winder shaft support is blocked or the
11034 supports not retracted limit switch was not activated.
11035 supports not swung in limit switch was not activated.
11036 supports not swung out limit switch was not activated.
Winder %1, load arm bolts not The load arm bolts are blocked or the limit
11037 retracted switch was not activated.
Winder %1, load arm bolts not The load arm bolts are blocked or the limit
11038 extended switch was not activated.
Winder %1, the hydraulic
pump's frequency inverter
coupling could not be There is no bus connection between the
11039 initialised controller and the frequency inverter.
Winder %1, primary nip: motor
11040 overtemp. The motor is overloaded.
Winder %1, primary nip: Em. An Emergency OFF switch or Emergency
Winder %1, primary nip: edge
strip suction motor protection
Winder %1, primary nip:
terminal box supply circuit
11043 breaker The circuit breaker has tripped.
Winder %1, primary nip: fault
11044 in FI The frequency inverter reports a fault.
Winder %1, primary nip: FI
11045 overtemperature The frequency inverter is too hot.
longitudinal knife oscillation
Winder %1, primary nip: no
11049 pull tension setpoint The setpoint must be increased.
Winder %1, primary nip: pre-
11050 treatment: general alarm The pre-treatment unit has a fault.
treatment: actual value
11051 deviation too great The pre-treatment unit has a fault.
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treatment cannot be switched The pre-treatment unit cannot be switched
11052 on on.
Winder %1, primary nip: fault The correct values could not be transferred
Winder %1, separation roller:
11060 motor overtemp. The motor is overloaded or blocked.
Winder %1, separation roller: An Emergency OFF switch or Emergency
11061 Em. stop activated OFF pull-cord has been activated.
11064 fault in FI The frequency inverter reports a fault.
11065 FI overtemperature The frequency inverter is too hot.
Winder %1, separation roller: The correct values could not be transferred
11076 fault during parameter transfer to the frequency inverter.
Winder %1, trim nip: motor
11080 overtemp. The motor is overloaded or blocked.
Winder %1, trim nip: Em. stop An Emergency OFF switch or Emergency
11081 activated OFF pull-cord has been activated.
11084 Winder %1, trim nip: fault in FI The frequency inverter reports a fault.
Winder %1, trim nip: FI
Winder %1, trim nip: no pull
11089 tension setpoint The setpoint must be increased.
Winder %1, trim nip: fault The correct values could not be transferred
Winder %1, trim nip: coupling There is no bus connection between the
11099 could not be initialised controller and the frequency inverter.
Winder %1, trim nip, spreader:
Winder %1, trim nip, spreader: An Emergency OFF switch or Emergency
Winder %1, trim nip, spreader
11102 2: motor overtemp. The motor is overloaded or blocked.
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11108 2: fault in FI The frequency inverter reports a fault.
11109 2: FI overtemperature The frequency inverter is too hot.
Winder %1, trim nip: spreader
2: fault during parameter The correct values could not be transferred
11115 transfer to the frequency inverter.
Winder %1, trim nip: spreader: There is no bus connection between the
11116 fault during parameter transfer controller and the frequency inverter.
2: coupling could not be The correct values could not be transferred
11118 initialised to the frequency inverter.
Winder %1, winder drum:

Winder %1, winder drum: pull- An Emergency OFF switch or Emergency
11161 cord switch activated OFF pull-cord has been activated.
edge strip suction motor
Winder %1, winder drum: fault
Winder %1, winder drum: FI
Winder %1, winder drum: film The film has wound itself around the drum or
11166 wound around drum the light barrier is incorrectly aligned.
The winder drum has been pressed back for
Winder %1, winder drum: more than 1 minute. CLP air pressure is too
11167 drum pressed to the rear low.
11168 static winding aid defective The high voltage generator reports a fault.
Winder %1, winder drum: no
Winder %1, winder drum: pre-
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treatment cannot be switched The pre-treatment unit cannot be switched
11172 on on.
Winder %1, winder drum: fault The correct values could not be transferred
Winder %1, spreader: motor
Winder %1, spreader: Em. An Emergency OFF switch or Emergency
Winder %1, spreader: fault in
11184 FI The frequency inverter reports a fault.
Winder %1, spreader: FI
Winder %1, spreader: fault The correct values could not be transferred
Winder %1, spreader:
Winder %1, central drive:
Winder %1, central drive: Em. An Emergency OFF switch or Emergency
Winder %1, central drive: fault
Winder %1, central drive: FI
Winder %1, central drive: fans
11206 monitor The motor is overloaded or blocked.
Winder %1, central drive
coupling did not open within The central drive's coupling could not be
11207 specified time opened.
coupling did not close within The central drive's coupling could not be
Winder %1, central drive: no
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Winder %1, central drive: fault The correct values could not be transferred
Winder %1, double centre
11220 drive: motor overtemp. The motor is overloaded or blocked.
Winder %1, double centre An Emergency OFF switch or Emergency
11221 drive: Em. stop activated OFF pull-cord has been activated.
11224 drive: fault in FI The frequency inverter reports a fault.
11225 drive: FI overtemperature The frequency inverter is too hot.
drive: fault during parameter The correct values could not be transferred
11236 transfer to the frequency inverter.
drive: coupling could not be There is no bus connection between the
Winder %1, switchgear
11240 cabinet fans monitor The motor is overloaded or blocked.
11241 cabinet temperature monitor Switchgear cabinet temperature is too high.
Winder %1, safety relay
11242 monitor The controller is not switched on.
The controller's battery must be replaced.
Winder %1, PLC battery The system should remain continuously
11243 monitor powered on.
Winder %1, air pressure
11244 monitor < 4 bar The air pressure is too low or missing.
Winder %1, winder supply unit The frequency inverter's supply unit is
11245 monitor defective.
Winder %1, fault while The display's built-in CAN interface could not
11246 initialising the CAN interface be initialised.
11247 Winder %1, no 230 V line feed The supply voltage is missing.
Winder %1, knife's longitudinal
oscillation motor protection
Winder %1, knife's transversal
oscillation motor protection
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Winder %1, vacuum pump

Winder %1, switchgear An Emergency OFF switch or Emergency
11251 cabinet Em. stop activated OFF pull-cord has been activated.
Winder %1, display screen An Emergency OFF switch or Emergency
Winder %1, data module with
11253 the options not found software program error
11254 initial values not found software program error
11255 the version not found software program error
11256 the alarm mode not found software program error
The coupling between 2 controllers is
11257 Winder %1, CAN I/O error interrupted
Winder %1, no supply feed to
11258 transformer
11259 Winder %1, UPS reports fault
Winder %1, shaft extractor:

11261 fault in frequency inverter The frequency inverter reports a fault.
11262 fuse in frequency inverter The fuse has blown.
Winder %1, shaft extractor: There is a conflict between shaft prisms of
11263 wrong prism selected winding shafts
Winder %1, shaft extractor: no
11264 shaft found The limit switch was not activated.
Winder %1, shaft extractor: An Emergency OFF switch or Emergency
11266 reset mode active Emergency mode is activated.
11267 not in base position The limit switch was not activated.
11268 ventilation fault The limit switch was not activated.
11269 prisms not open The limit switch was not activated.
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Winder %1, shaft extractor: The coupling between 2 controllers is

11270 CAN I/O error interrupted
data module with initial values
11271 not found software program error
11272 ventilation valve not retracted The limit switch was not activated.
shaft supports motor
Wider %1, shaft extractor: An Emergency OFF switch or Emergency
11276 shaft support Em. stop OFF pull-cord has been activated.
shaft support not in base
11277 position The limit switch was not activated.
11278 shaft support not on shaft The limit switch was not activated.
tube cylinder not in base
11280 Winder %1, roll cart: fuse The fuse has blown.
Winder %1, roll cart: motor
Winder %1, roll cart: safety
11282 bumper The roll cart is standing at an obstacle.
Winder %1, roll cart: not in
11283 base position The limit switch was not activated.
Winder %1, roll cart: flap not
11284 in base position The limit switch was not activated.
11285 Winder %1, service mode: Service mode has been activated.
Winder %1, roll cart: pallet
11286 sensor not activated The limit switch was not activated.
Winder %1, roll cart: hydraulic
11287 pump MPS The motor is overloaded or blocked.
Winder %1, roll cart: roll cart
11288 table arrived at top The limit switch was not activated.
11289 table not in base position The limit switch was not activated.
Winder %1, roll cart: CAN I/O The bus connection between 2 controllers is
11290 error interrupted.
Winder %1, interm. nip: motor
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Winder %1, interm. nip: Em. An Emergency OFF switch or Emergency

Winder %1, interm. nip: fault
Winder %1, interm. nip: FI
Winder %1, interm. nip: fault The correct values could not be transferred
Winder %1, interm. nip:
Winder %1, cooling roller
11320 train: motor overtemp. The motor is overloaded or blocked.
Winder %1, cooling roller An Emergency OFF switch or Emergency
11321 train: Em. stop activated OFF pull-cord has been activated.
11324 train: fault in FI The frequency inverter reports a fault.
11325 train: FI overtemperature The frequency inverter is too hot.
train: coupling could not be There is no bus connection between the
Winder %1, CAN I/O fault The bus connection between 2 controllers is
11340 report interrupted.
Winder %1, coupling to roll The bus connection between 2 controllers is
11341 cart interrupted interrupted.
11342 Winder %1, local I/O error The controller reports a fault.
Winder %1, coupling to take- The bus connection between 2 controllers is
11343 off interrupted interrupted.
Winder %1, standard base
11344 parameters not found software program error
Winder %1, standard base Standard base parameters have been
11345 parameters loaded loaded.
Winder %1, coupling to other The bus connection between 2 controllers is
11346 winder interrupted interrupted.
Winder %1, frequency inverter
Winder %1, "Deposit point The operator has activated the "Ignore
11348 occupied" message ignored deposit location" function.
11349 Winder %1, version conflict software program error
Winder %1, motor protection
11351 switch (collective fault) A motor is overloaded or blocked.
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Winder %1, interm. take-off

11600 tempering unit too cold The temperature is too low.
11601 tempering unit too hot The temperature is too high.
11602 tempering unit fault The tempering unit reports a fault.
Winder %1, primary nip
Winder %1, cooling roller train
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3.11 Recipes
A recipe contains all relevant setpoints and settings for a product. Once a recipe has
been created, the operator can load it into the machine at any time or even only
check its current settings. Sending recipes to the machine is a two step process for
safety.
Before an automatic download, be sure you are doing the right thing!
Differences between current settings and the selected recipe are displayed in the
"recipe" column with a green background.
Parameters are divided into groups as
follows:
temperature
dosage
yield
controls
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The selected recipe's selected group will

be transferred into the machine.
The selected recipe can be changed.
Such a change is only temporary but can
also be stored.
Only the marked value will be transferred
to the machine.
An overview of all recipes can be printed
or displayed in tabular form.
An individual recipe can be printed out
with all of its setpoints.
A recipe can be stored to a data media as
a backup (export) then later on imported
again whenever it is needed.
A recipe can be deleted.
The selected recipe will be loaded into an
intermediate memory.
The system's current settings will be
stored in a recipe.
Recipes should always be stored (exported).
Before an automatic transfer of values, be sure you are doing the right thing!
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3.11.1 Recipe handling

If the operator is satisfied with the machine's settings, he can store all current
setpoints, including the order data which has been entered, under a freely selectable
name. ("recipe store" button) along with entry of the recipe's name, creator, date and
comments).
When the operator wishes to run this product again, he can load it again.
The operator can transfer setpoints individually (data point to machine) or in groups
(select "temperature" then "recipe to machine").
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3.12 Trend
The trend function records all of the system's current values.
Certain trends (Kiefel trend) are permanent and these can be called up via function
keys. Trends can also be freely compiled.
As many as 6 values can be displayed in up to 6 levels simultaneously.
The current display can be:

• stretched
• moved
• enlarged
• reduced
• traced
The trend variable is scaleable in the
presentation.
Alarm limits can be defined for average

thickness, width and 2 sigma. An alarm
will be issued if these limits are
exceeded.
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Historical values can be displayed with

the history function.
After making entries for the date (Amer.
format), time of day and duration,
activating the "history" control will display
the historical values.
A production protocol for a selected value
to a freely selectable point in time can be
printed out, provided that the system was
switched on at the time.
The printout can take several minutes.
A system's values are stored every 2 minutes.
A system's values remain stored for up to 1 year.
3.12.1 Trend selection

The operator can compile a freely selected trend by using the "trend selection"
function.
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Deletes all previous selections and permits the compilation

of a new trend
Permits the storage of selected values for use later on as a
group of values
Calls up a select group of values which have been stored
Deletes the selected group
A group of values can be assigned to function keys within

the trend
The "selection" column determines the sequence for the value in the trend to be
produced. Up to 6 values can be selected. These 6 values can be assigned to 6
rows.
Entries in columns "max" and "min" permits preliminary value scaling in the
presentation.
3.12.2 Trend alarms

12300 Thickness outside limits With controls switched on, the thickness value
has gone out of the limits.
The alarm limits are defined in the trend.
13505 2Sigma outside limits With controls switched on, the 2Sigma value
has gone out of its limits.
14001 Width out of limits With width regulation switched on, the
difference between setpoint and actual value
for width is too great.
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3.13 Pellet supply

The pellet supply unit controls the material fed into the extruder. A feed cycle is time
controlled. The pellet hoppers are repeatedly filled in cycles until the hopper flap
gets stuck in material.
A feed circuit consists of a suction blower with a bypass valve and a fixed number of
pellet hoppers. The number of feed circuits, i.e. the number of pellet blowers,
depends on the given plant.
If the hoppers in a given feed circuit simultaneously request to be filled, the filling will
be done in sequence.
Optionally a cleaning cycle can be performed by way of a pre-filter (cleaning hopper).
start / stop pellet supply
Empty hoppers have one-time priority to be filled.
Shows current fill levels. This display is only available with

the "residual quantities management" option.
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The colours indicate status as follows:

• grey: full
• blue: pending demand
• red: empty
Pre-selection has 3 possible status conditions:

• On: The hopper will be filled.
• Off: The hopper will not be filled.
• Auto: This is an option available with "residual
quantities management". Feeding will be switched off
automatically at the end of the order.
3.13.1 Pellet supply alarms

10101 Hopper %1, is empty The lower limit switch reports no pellets.
10102 Supply blower %1, fault The supply blower's motor protection switch
has activated.
10103 Hopper %1, supply alarm This alarm is issued if the hopper is full but the
conveyor flap does not swing down after this
fill cycle.
10105 Hopper %1, auto filling has This alarm is specific to the "residual quantities
switched off management" option and indicates the filling of
this hopper has been switched off.
19007 Main controller PLC CAN Fault in the CAN bus connection.
node, pellet supply missing
19008 Main controller PLC CAN The PLC reports an error code. This error code
node, pellet supply, error: %2 can be looked up in the B&R handbook.
Add: %3
node 2, pellet supply missing
node 2, pellet supply, error: can be looked up in the B&R handbook.
%2 Add: %3
node 3, pellet supply missing
node 3, pellet supply, error: can be looked up in the B&R handbook.
%2 Add: %3
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3.14 Heating
Each extruder and the die-head has an independent heater regulator. Heating zones
are generally assigned in the direction of production. Each heating zone has a
setpoint entry, actual value display and a ratio display. Negative ratios indicate
cooling by way of a blower. The electric current passing through heater bands is
monitored sequentially.
There are various operational states to be set by the

operator:
• heater on
• heater off
• reduction extruder and/or die-head
Heating zones are set to fixed setpoints
(normally 100 °C). These functions should be
activated when the plant is at a standstill for an
extended period to prevent an outbreak of fire.
Multiple heating zones can be marked then an entry
made which is applicable to all selected heaters, this
simplifies the entry process.
3.14.1 Heating alarms

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10001 Extruder A, Zone 1, current The measured electric current in a heating

alarm zone is out of tolerance (too great or small).
10002 Die-head, Zone 1, current The measured electric current in a heating
alarm zone is out of tolerance (too great or small).
10003 Extruder A, Zone 1, The heating zone is too hot.
temperature too high
10004 Die-head, Zone 1, The heating zone is too hot.
temperature too high
10005 Die-head, Zone 1, The heating zone is too cold.
temperature too low
10006 Die-head, Zone 1, The heating zone is too cold.
temperature too low
10007 Extruder A, Zone 1, short The heating zone will not heat but there is
circuit current flow. Power will be removed from the
entire heater.
10008 Die-head, Zone 1, short The heating zone will not heat but there is
circuit current flow. Power will be removed from the
entire heater.
10009 Extruder A, Zone 1, sensor The temperature sensor is interrupted.
break
10010 Extruder A, Zone 1, sensor The temperature sensor is interrupted.
break
10013 Extruder A, Zone 1, auto- Optimisation of this heating zone was faulty.
tuning faulty
10014 Die-head, Zone 1, auto- Optimisation of this heating zone was faulty.
tuning faulty
10015 Extruder A, Zone 1, Delta When the temperature sensor has no contact
Theta monitoring to the hot part, this monitor will prevent
continuous heating. Power will be removed
from the entire heater.
(If heating is on at a rate over 90 % for an
hour and temperature has not increased by at
least +10 °C.)
10016 Die-head, Zone 1, Delta When the temperature sensor has no contact
Theta monitoring to the hot part, this monitor will prevent
continuous heating. Power will be removed
from the entire heater.
(If heating is on at a rate over 90 % for an
hour and temperature has not increased by at
least +10 °C.)
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10017 Extruder A, Zone 1, The maximum permissible temperature has

maximum temperature been exceeded. Power will be removed from
exceeded the entire heater.
10018 Die-head, Zone 1, maximum The maximum permissible temperature has
temperature exceeded been exceeded. Power will be removed from
the entire heater.
10060 Extruder A, heater switched The heater is switched off when various
off alarms occur, i.e. power is removed.
10060 Die-head heater switched off The heater is switched off when various
alarms occur, i.e. power is removed.
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3.15 Profile measurement and control

Profile measurement is prerequisite to profile control.
3.15.1 Profile measurement
Profile measurements differ by virtue of their measuring principle and installed

location. Just which profile measuring technique is used depends on the product and
structural conditions. All profile measurement techniques detect 360 values around
the die-head This also applies to the profile measurements downstream of the layflat.
Extra keypad
Profile measurement can only be switched on via the
extra keypad.
The following data elements are provided for every profile

graph:
• maximum positive and negative deviation from mean
film thickness in µm and %
• 2 Sigma value in µm und %
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The display can be normalised:

- max. discrep. maximum display
- tolerance: deviations greater than this value will be red
- measured mean thickness
These control buttons allow the

display of time offset profiles as a
circle diagram.
3.15.1.1 Profile measurement alarms

If the profile is much worse with activated
control as the last profile then control will be
put on hold.
If the unregulated profile is better, profile
Profile measurement is control will be switched on again.
12301 instable, profile control will The limit for this can be set in the "service"
be suspended screen.
If film thickness changes during a profile
measurement cycle, profile control will be
Film thickness is instable, suspended.
profile control will be The limit for this can be set in the "service"
12301 suspended screen.
Profile measurement No communication to profile measurement.
13504 coupling interrupted
The following alarms are generated by various profile measurements. Their details
can be found in the profile measurement manual.
13650 Profile measurement: endbub/measuring position not reached
13651 Profile measurement: end home position not reached
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13652 Profile measurement: film bubble too small

13653 Profile measurement: film bubble too big
13654 Profile measurement: no measurement values from C head
13655 Profile measurement: temperature C head failed
13656 Profile measurement: motor does not turn
13657 Profile measurement: bubble scanning impressed
13658 Profile measurement: bubble scanning failed
13659 Profile measurement: C head too hot
13660 Profile measurement: C head dirty
13661 Profile measurement: C head frequency too low
13662 Profile measurement: C head frequency instable
13663 Profile measurement: time initialization expired
13664 Profile measurement: left limit switch / tooth counting failed
13665 Profile measurement: right limit switch / tooth counting failed
13666 Profile measurement: tooth counting failed
13667 Profile measurement: tooth counting instable
13668 Profile measurement: max time rot. right expired
13669 Profile measurement: max time rot. left expired
13670 Profile measurement: EOS not found
13671 Profile measurement: profile too old
Profile measurement: measurement error (measuring frequency too
13672 low)
Profile measurement: measurement error (measuring frequency too
13673 high)
13674 Profile measurement: measurement error (plausibility check)
13675 Profile measurement: zeroing distance too short (film bubble too large)
13676 Profile measurement: telescoping drive defective
Profile measurement: measurement error (frequency during zeroing too
13677 low)
Profile measurement: measurement error (frequency during zeroing too
13678 high)
13679 Profile measurement: measuring electronics defective (power supply)
Profile measurement: measuring frequency missing (measuring
13680 electronics or data cable defective)
13681 Profile measurement: rotation signal error
Profile measurement: minimum rotation time exceeded (rotation still
13682 active)
13683 Profile measurement: minimal rotation time exceeded (rotation stopped)
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Profile measurement: telescope arm retracted because front limit switch

13684 reached (film bubble torn off or too small)
13685 Profile measurement: no communication with control system
3.15.1.2 2 Sigma
The 2 Sigma value is the double standard deviation and is calculated by the
controller as follows: Kirion C uses 360 measurement values over the double foil
width.
360 X = individual measurement value [µm]
∑1 ( X − X )
2
X = mean of 360 measurement values
2σ = 2 * σ = sigma.
359
Profile control
There are fundamentally 3 different types of profile control:
• C1
control of air volumes on a segmented cooling ring
• C2
control of air temperatures on a segmented cooling ring
• C3
control of die-head temperatures on a segmented die-head
Profile control follows a simple rule:
film areas which are hotter when they come out of the tool are stretched more and
are therefore thinner. Thus targeted heating or cooling in individual segments can
help to adapt thickness distribution around the bubble's circumference.
Control can be switched on and off. In "hold" mode the

heating elements remain at the fixed value.
Display of heating power percentage for a segment.
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3.15.2 Profile control alarms

Heater cartridge %1, faulty / The heater cartridge's current consumption is too
13500 too much current high.
Heater cartridge %1, wire A heater cartridge's current consumption is too
13501 break / too little current small or the electric circuit is interrupted.
Heater cartridge %1, short
13502 circuit The solid state relay is defective.
Coupling to profile servo No communication between profile servo
13503 components faulty components and controller
Profile measurement No communication between profile measurement
13504 coupling interrupted and controller
The preset alarm limits for profile control have
been exceeded with profile control switched on.
The limits are set in "trend" on the "2Sigma"
13505 2Sigma outside limits screen.
13506 components 2 faulty components and controller
Profile control must not be switched on. The cause
13686 No profile control enable may be that the cooling ring blower is not running.
13687 Profile control switched off
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3.16 Alarm display

Currently pending alarms are displayed when the "alarms" screen is called up.
These alarms are made visible from a distance by virtue of a signal light or
acoustically signalled by a horn. When an alarm occurs, the signal lamp will blink until
the alarm is acknowledged.
Alarms are further subdivided into warnings (orange), fault (red) and status display
(white). A principle distinction is made between non-self-acknowledging alarms and
those which are self-acknowledging.
• Non-self-acknowledging alarms must be acknowledged. As soon as this alarm is
no longer pending and is acknowledged, it will be removed from the list of current
alarms.
• Self-acknowledging alarms need not be acknowledged. When this type of alarm is
no longer pending, it will be deleted automatically from the list of current alarms.
A single row in the table is reserved for every alarm. The alarm row contains the
following information:
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The first two columns contain a display of the error

text and the corresponding error number. Error
numbers are unique and the same for all languages.
The next three columns contain a display of the
date/time stamp for each change of error status:
• began
• ended
• acknowledged
If an alarm is begun, ended and acknowledged, it will be removed from the list of
current alarms.
Some alarms must be acknowledged by the operator, other alarms are removed
automatically from the list when they are no longer active.
3.16.1 Alarm handling

This control button acknowledges alarms.
+
By marking an entry in one column, only those values are
displayed. The following filters are available:
error no.
error status (began, ended, acknowledged)
date/time stamp (all alarms within the selected hour)
Entries will be sorted according to the selected column.
Alarm history is displayed for all alarms by days. A

particular date can be selected by paging through the list
with the "day +/-" or "week +/-" control buttons.
The "print" control button will produce a printout of the

given display of alarms.
A selected alarm can be deleted in the "history" or
"statistic" views.
This function is password protected.
All alarms which have a particular error number (= alarm
group) can be deleted in the "history" or "statistic" views.
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All alarms for a given displayed day can be deleted in the

"history" view.
This control button will print the current view.
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3.17 Order
Order management is an option. This function collects all specific information for an
order. Specific information includes material consumption and electric energy. If a
Kiron winder is integrated into the plant, a report will be generated for every roll.
The order metre counter is a part of each screen.

The upper value is the setpoint for the order.
The lower value is the current value for the order.
This control button permits a new order to be created.
+ The maximum number of orders is limited to 100.
This control button will call up the selected order.
The selected order can be edited.
This control button will delete the selected order.
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Consumables for the last week or last month will be displayed.
The order metre counter is started with the winder 1/2 start
counter control button.
An order is based on a length to be produced. An order can be created by activating

the "new" control button then filling out the fields of the window which opens. If an
order is to be run with edge trim, the net width must be specified.
Important: If the order is to be run without edge trim it is imperative to enter net
width as "0 mm".
When an order is created the rolls currently on the winder are automatically
counted toward this new order.
The order metre counter runs only if the metre counter on the winder is
switched on. Consumption data are stored under the header "production".
If the metre counter is switched off, consumption data will be stored under the
header "conversion".
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3.17.1 Details of order
The "total" column contains the sums for the columns production, conversion and
standstill.
standstill no extruder drive running

conversion an extruder and take-off are running,
the metre counter on the winder is switched off
production an extruder and take-off are running,
the metre counter on the winder is switched on
total sum of standstill + conversion + production
efficiency = production / (standstill + conversion + production)
The current overview will be printed out.
The data will be written to diskette and can be post-processed,

e.g. with Excel.
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3.17.1.1 Roll report
The first column contains information about when the production took place and
which winder produced the roll. If the field net width ≠ 0 for the order, the entered set
width is used for calculation.
The operator will have an opportunity to enter a brief remark for each roll in the entry
field line near the bottom of the screen.
The current overview will be printed out.
All roll reports for the order will be printed out.
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3.18 Residual quantities management

The "residual quantities management" function is a part of pellet supply and order
management. This function is intended to ensure that at the end of an order there is
as little granulate remaining in the system as possible.
A calculation is made on the measured material quantity in the dosing hopper and
the volume in the pellet hopper. The quantity is calculated on the volume in the pellet
hopper and the bulk weight from the material database.
Shows current fill levels. This display is

only available with the "residual quantities
management" option.
The colours indicate status as follows:
grey: full
blue: pending demand
red: empty
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Pre-selection has 3 possible status

conditions:
On: The hopper will be filled.
Off: The hopper will not be filled.
Auto: This is an option available with
"residual quantities management".
Feeding will be switched off automatically
at the end of the order.
The hopper will no longer be full at the

end of the order.
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3.18.1 Residual quantities management alarms

10105 Hopper %1, auto filling has This alarm is specific to the "residual quantities
switched off management" option and indicates the filling of
this hopper has been switched off.
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3.19 Week and month report

The week or month report is a part of order management. Consumption figures for
material and electric energy over the previous week or month will be displayed.
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3.20 Production protocol

Activating this control button will cause a printout of all important plant settings in a
form.
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3.20.1 Production protocol history

A production protocol for a period in the past can be printed by activating the
"protocol production" control button in the "trend" screen.
A production protocol for a selected value

to a freely selectable point in time can be
printed out.
The printout can take several minutes.
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3.21 Servicing
Necessary maintenance procedures will be displayed. A background timer runs for
each maintenance procedure. When a procedure's timer expires, the displayed
procedure is to be performed and its completion is to be acknowledged. The
maintenance interval will be restarted after the acknowledgement.
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3.22 Elapsed time counter
There are 2 elapsed time counters for each plant section.

The upper elapsed time counter shows overall accumulated runtime for the given
plant section.
The lower elapsed time counter shows accumulated runtime for the given plant
section since the counter was last serviced (and this counter can be reset).
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4 Service and parameter settings

A majority of plant parameters can be set by way of the service screens. These
service screens also help to perform troubleshooting and analysis. A data backup
feature is also implemented.
4.1 Password entry

A password is generally needed in order to enter or change parameters.
A login can be done by activating the Kiefel LOGO in the upper left corner of the
screen.
There are 3 different password levels for access to individual parameters:

PW Level 0 no password necessary
PW Level 1 Maintenance personnel password. This
password should be reserved for trained
service personnel only.
PW Level 2 for Kiefel personnel only
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4.2 General parameters

4.2.1 Language selection
See "service" screen, PW Level 0
The desired language for operating the system can be selected in this window.
ATTENTION: Selection of one of the following languages requires that the

computer be rebooted:
• Russian
• Chinese
• Greek
• Korean
4.2.2 Units of measure selection

Selections can be made between the following measuring units:

Temperature °C °F
Pressure bar psi
Weight kg lb
Throughput kg/h lb/h
Metre weight g/m lb/1000ft
Distance m ft
cm in
µm mil
Speed m/min ft/min
Pull N Lb
Recipes and parameters are stored in the given unit and are therefore
incompatible.
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4.3 Extruder
4.3.1 Extruder designations
A code in the upper field (no longer than 2 characters) should be used to designate
an extruder. This change also has an effect on the production protocol.
The lower field is for entry of extruder size and appears only on the overview.
4.3.2 Extruder drives

See "service extruder X" screen, PW Level 1
Torque displays [Nm] are based on the value entered for maximum torque value
"torque max." [Nm].
Extruder drives can be limited by setpoints for max. [%] and min [%]. The current
setpoint is also displayed in %.
The fields for rotary speed are only relevant when there is no attached dosing unit.
In this case the screw speed sensor is connected directly to the extruder's PLC. The
number of gear teeth per rotation is to be entered into the field "pulses/rotation". The
"input frequency" field shows the raw input value (pulses/s). The normalised field
produces the displayed speed.
Speed should be calculable with the equation:

tooth count = input frequency*60/rotations measured manually
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4.3.3 Extruder melt pressure

There are up to 2 melt pressure sensors. Sensor 1 is upstream of the screens,
sensor 2 is downstream of the screens.
The measurement range value [1000 bar] is that of the melt pressure sensor. This
measurement range value is to be taken from the sensor datasheet. The sensor must
have an 4 ... 20 mA current loop electrical output, which corresponds in pressure
from 0 bar to the measurement range value.
A warning will be generated at the "pre-alarm value" setpoint [600 bar]. The extruder
will be shut down at the setpoint for "shut-down value" [700 bar].
The "pressure diff. max" setpoint [200 bar], grouped under the 2nd melt pressure
sensor, is the pressure difference allowed between the two sensors. An alarm will be
generated if the pressure difference exceeds this setpoint value .
4.3.3.1 Extruder melt pressure calibration

Normally the melt pressure sensors are already calibrated when delivered.
Recalibrate only if necessary.
Calibration may only be done when the extruder is switched off (no pressure).
Calibration offset: The normal display value is set to 0.

Calibration shunt: There is a resistor inside the sensor that simulates an output value
equivalent to 80 % of full measurement range. This is used to calibrate the display to
80 % of the full measurement range, i.e. for a pressure sensor rated for 1000 bar,
800 bar will be displayed.
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4.3.4 Extruder pellet monitoring

Pellet monitoring is done directly above the feeder to detect the presence of pellets.
After a delay time of 2 seconds a warning will be generated. In conjunction with rotary
speed, the extruder will be shut off after this delay. For example, if the extruder is
running at 50 rpm, it will be shut down after 12 seconds. If it is desired to not stop the
extruder in case of a pellet loss, set the values to 0.
4.3.5 Extruder grooved bushing tempering unit

The alarm tolerance [5 °C] for reporting tempering unit conditions too hot or too cold
can be adjusted in the "discrep." field. Regulation factors (proportional and integral)
can be set for heating and cooling. A negative "regul. ratio" means cooling.
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4.4 Cooling ring and IBC blower

See "service: Blow Film Die Air Ring" screen, PW Level 1
Various ramps can be set for each blower. Ramp time is the acceleration time or
braking time to traverse 100 % of setpoint value.
• ramp manual [20 sec]
acceleration via the +/- controls in the extra keypad.
• ramp master stop [10 sec]
braking ramp per master stop function
• ramp setpoint [20 sec]
acceleration for setpoint specification via the screen.
• ramp yield [120 sec]
Both blowers will be adjusted by way of the +/- yield control keys.
This time is applicable for the USB (ultrasonic bubble) option with blower post-
regulation.
The setpoint specifications can be limited by the values "rotation speed min" [0%]
and "rotation speed max" [100%].
4.4.1 USB blower regulation

See "service: USB" screen, PW Level 1
This setting provides post-regulation for the exhaust blower so that the USB valve
can operate in its optimal range. If the USB valve is >20 % out of its middle position,
the exhaust blower is post-regulated until the valve is <15 % out of its middle
position.
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4.4.2 Cooling units

See "service: Blow Film Die Air Ring" screen, PW Level 1
Air tempering units from external vendors can be connected to Kirion. The settings
made here normalise the analogue signals to the correct display values.
The entries for actual values -10 °C and 40 °C are intended for to 0 ... 10 V or 0 ...
20 mA analogue outputs. The same applies to setpoint output values 5 °C to 40 °C
with 0 to 10 V. Please follow the instructions provided by the vendor.
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4.5 USB
See "service: USB" screen, PW Level 1
USB stands for Ultra Sonic Bubble control.
4.5.1 USB valve
The working range of the valve can be set between min [0]% and max [100]% values.
The spread range is the green area of the bar graph. 40 % means
that the green area extends from 30 to 70 %.
4.5.2 USB sensor
The distance of the moveable sensor to the inner side of the calibration basket rollers
is 150 mm. All 3 sensors must have the same distance. This value can be adjusted to
control the film contact in the calibration basket
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The 3 actual values show sensor analogue values in a range of 0 to 32 767. This is
the measuring range of the sensor.
4.5.3 USB regulation parameters
These regulation parameters are only for Kiefel internal purposes.
4.5.4 USB blower regulation
This setting provides post-regulation for the exhaust blower so that the USB valve
can operate in its optimal range. If the USB valve is >20 % out of its middle position,
the exhaust blower is post-regulated until the valve is <15 % out of its middle
position.
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4.6 Calibration basket

See "service: USB: basket" screen, PW Level 1
4.6.1 Calibration basket with diameter acquisition
Basket diameter is monitored by a potentiometer. A potentiometer's voltage is

measured at the PLC input then displayed on-screen as "basket diameter" [0.0 V].
Measured voltage increases proportionally with increasing basket diameter.
The entries for individual voltage values is done in mmdfl.

mmdfl = 3.14 * diameter [mm] / 2
m m dfl
1200
1000
800
600
400
200
0
0 2 4 6 8 10 12 Volt
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The above values determine speeds and the accuracy of the basket diameter to be
established.
When a new setpoint is specified, the basket will only adjust within the preset
hysteresis.
basket open/close = setpoint – actual value > hysteresis
The basket switches over to fast speed as soon as
setpoint – actual value > fast adjustment
4.6.2 Calibration basket without diameter acquisition
These preset values are only relevant when the system has a width measuring
function.
Basket min [mmdfl] is the minimum width that can be set for the basket.
Basket max [mmdfl] is the maximum width that can be set for the basket.
The calibration basket's characteristic can be modelled on the basis of the support
points and the time measured between support points.
The procedure is as follows:
It is a "linear basket", i.e. the adjustment is performed linearly over time.
basket min is 1000 mmdfl
basket max is 1800 mmdfl
The measurement is made via basket diameter. This derives the lay width.
mmdfl = 3.14 * diameter [mm] / 2
The adjustment time between 1000 and 1400 mmdfl is 20 seconds.

The adjustment time between 1400 and 1800 mmdfl is 20 seconds.
displayed Delta support points 400 mmdfl
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The entry values are as follows:

Number of support points: 2
support point 1: 20 sec.
support point 2: 20 sec.
m m dfl [m m ]
2000
1800
1600
1400
1200
1000
800
600
400
200
0
0 20 40 sec
4.6.3 Calibration basket with cage height display
Both end positions for calibration basket up and calibration basket down will be
acquired by the controller and, together with the entered values for "cage height max"
and "cage height max", determine the adjustment range. The actual position is
determined by counting pulses with a proximity switch.
The calibration basket must be moved between its end positions up and down
as a one-time procedure during commissioning or after a controller has been
replaced.
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4.7 Width measurement

See "service: width control" screen, PW Level 1
The entire range of the width measurement bar is to be entered into the "width" field.
Width measurement can be corrected as follows:
New entry value = entry value + displayed setpoint – displayed actual value
4.7.1 Width measurement status display
The left digit shows the status of the left measurement bar. The right digit shows the
status of the right measurement bar. A leading zero will be suppressed in this display.
Display
0 status OK
1 no more measurement values
2 measurement value out of limits
3 limit switch triggered
4 test % EOS triggered
5 CART DOES NOT MOVE
6 FILM SENSOR DEFECTIVE
7 FILM TOO WIDE
8 NO FILM
9 NO COMMUNICATION WITH WIDTH NODE
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4.8 Width regulation

See "service: width control" screen, PW Level 1
The distance between die-head and width measurement [25.0 m] must be

entered during commissioning. This distance corresponds to the film path
from the melt outlet.
These regulation parameters are only for Kiefel internal purposes.
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4.9 Take-off
See "service: take-off" screen, PW Level 1
If the take-off has its own local control panel, parameterisation is to be done on that
panel.
actual maximum take-off speed (100%)
operator's maximum speed setpoint entry
4.9.1 Take-off reversal

See "service: take-off" screen
Actual position display (per number of counted gear teeth) for reversal.
4.9.2 Take-off layflat display

minimum and maximum entry values
4.9.3 Take-off central guide display

minimum and maximum entry values
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4.9.4 Take-off gusset or side guide display

minimum and maximum entry values for bottom and top
4.9.5 Take-off tempering unit

The alarm tolerance [5 °C] for reporting tempering unit conditions too hot or too cold
can be adjusted in the "discrep." field. Regulation factors (proportional and integral)
can be set for heating and cooling. A negative "regul. ratio" means cooling.
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4.10 Dosing
See "service: extruder" screen
Service and parameter settings differ greatly for individual systems and must be
taken from the given dosing system's own documentation.
4.10.1 Shrinkage calculation

See "service: other" screen, PW Level 1
This is an option for correcting the actual running metre weight display. This
correction may be made necessary due to shrinkage between take-off and winding,
because of errors in diameter measurement, or because of take-off speed
measurement.
Displayed running metre weight will be corrected by the factor:
displayed actual value [g/m] = measured actual value from dosing [g/m] / (correction
factor/100).
An automatic correction is made with the option "shrink calculation" by measuring

winder speed.
Additionally, a manual entry for correction factor [100 %] is also possible.
The composite correction factor is derived by multiplying the automatically assessed
correction factor (winder speed to take-off speed) and the correction factor entered
manually.
The cause of falsely displayed running metre weight may also be from an
incorrectly displayed throughput. When use of a correction factor is needed,
the weigher cells in the dosing mechanism should be checked. It is also
important that correct take-off speed is displayed. Also, the correct material
density must be checked.
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4.11 Winder
4.11.1 WM winder
See "service: winder" screen
ROLL DIAMETER Shows the roll's actual diameter.

LOAD ARM DOCKING Docking speed of the load arm. In percent, 0 ... 100%
SPEED
LOAD ARM RETRACTION Retraction speed of the load arm. In percent, 0 ... 100%
SPEED
LOAD ARM GAP / CLP Load arm interval speed for CLP intervals. In percent, 0
SPEED ... 100%
LOAD ARM RETRACT Time delay for the load arm to reach its docking position.
DELAY TIME This time allows the deposited roll to securely roll out of
the load arm.
3 INCH CUT DELAY TIME Delay time for crosswise separation of the film when 3
inch cores are in use. This delay can be used to
determine if and how long the new core is to be run onto
the material web before the cut takes place.
6 INCH CUT DELAY TIME Delay time for crosswise separation of the film when 6
inch cores are in use. This delay can be used to
determine if and how long the new core is to be run onto
the material web before the cut takes place.
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WATCH TIMER FOR If the magazine is empty, a new shaft must be put into
the magazine and the crane retracted out of the way
MAGAZINE MOVE within this period of time!
PRESET TIME FOR The initiation of a roll change will be advanced by this
ROLL CHANGE amount of time in automatic mode.
ELAPSED TIME
Shows elapsed operating hours.
COUNTER
The sensing lever, which monitors the shaft in the
magazine and roll diameter in the pivot arm, must be at
its, spring loaded, upper limit.
CALIBRATION ENCODER This encoder calibrates itself again every time the
ON LOAD ARM winder is switched on!
When powering up the sensing
lever must always be in its upper
limit position!
The load arm must come to rest on the winder drum
when there is no winder shaft.
Switch pulses on for at least 5 seconds then off again.
CALIBRATION ENCODER
offset = 55 ( +/- 0.5)
ON LOAD ARM
⇒ Switch the machine off.
The new value will only be adopted after power has
been switched off!!
Shows the actual load arm encoder value. offset = 55°
ENCODER VALUE
( +/- 0.5)
LODE DEFAULT This control button causes an initialisation file to be
PARAMETERS created.
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4.11.2 WS winder
See "service: winder" screen
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4.12 Pellet supply

4.12.1 Pellet supply hopper feed time
See "service: blower hopper" screen, PW Level 1
Feed times are entered here for each hopper.
4.12.2 Pellet supply warning

See "service: blower hopper" screen, PW Level 1
The upper time is a delayed trigger to signal the empty condition. Prerequisite for this
is a corresponding empty condition switch in the pellet hopper.
The lower time is the interval between 2 feed cycles for the hopper and represents
the time required for the material to fall into the hopper after a suction cycle.
4.12.3 Pellet supply blower settings

See "service: blower hopper: service blower" screen, PW Level 1
Setting for the blower's delay time. This interval prevents simultaneous startup of all
blowers and is also the blower's time for star-delta startup.
The bypass delay time is the time between switching the feed valve of a pellet hopper
and switching the bypass valve.
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4.12.4 Pellet supply cleaning function

See "service: blower hopper: service blower" screen, PW Level 1
If a pre-filter (separator or cleaning hopper) is present in the system, a 10 second

vacuum will be build up after 50 feed cycles. This vacuum is discharged across the
pre-filter to clean the feed hopper's filter or sieve.
4.12.5 Pellet supply residual quantities management

See "service: blower hopper" screen
This is where hopper quantities (volume) are to be entered if the residual quantities
management option is present in the plant.
The upper value is the quantity (1 dm³ = 1l) between the feed valve and pellet empty
report. The lower value is the volume between empty report and dosing hopper.
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4.13 Heating
See "service extruder X: zone X" screen, PW Level 1
See "service: Blow Film Die Air Ring: zone X" screen, PW Level 1
The parameter setting procedure for a die-head's heating zone is identical to that of
an extruder's heating zone. Differentiation is only made between 2-point (heating
only) and 3-point (heating and cooling). There are different parameters for heating
and cooling.
4.13.1 Heating zone minimum and maximum setpoints

Display [150 °C] of the minimum setpoint entry for the operator.
Display [250°C] of the maximum setpoint entry for t he operator. This maximum
setpoint limit prevents temperatures which are too high. If a heating zone's actual
temperature exceeds this value by 30 °C (>280 °C) l ine power will be removed from
the heater as a safety precaution.
4.13.2 Heating general shutdown

See "service" screen
If a major fault occurs (short circuit or Delta Theta), heaters will be disconnected from
line power when this period expires.
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4.13.3 Heat-up
The temperature ramp brings heated metal bodies up to temperature evenly. This
function prevents stresses from occurring in the bodies to be heated. The ramp
affects only the setpoint and is transparent to the operator. Individual ramps can be
established for each extruder as well as for the die-head.
This is a factory setting that cannot be changed.
heating ramp
200
150
°C 100
50
0
0 50 100 150 200
min
The diagram above shows the course of the setpoint during the heat-up phase.
Temperature ramp 1 is active for setpoints less than 150 °C. Temperature ramp 2 is
active for setpoints greater than 150 °C.
When the heater is switched on, all temperature setpoints will be set internally to the
actual temperature; heating-up will subsequently be done with the actual temperature
ramp.
The currently active setpoint for every heating zone can be checked on the service
screens.
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4.13.4 Heating zone activation

See "service: extruder" screen, PW Level 1
See "service: extruder: Blow Film Die Air Ring" screen, PW Level 1
Each heating zone can be made active or passive.

Passive heating zones display only actual temperatures.
ATTENTION: Passive heating zones are not monitored and do not prevent the
extruder from being switched on (cold start lockout).
4.13.5 Heating zone temperature settings

set This setpoint is active when heating is switched on and the

setpoint plant is running.
set This setpoint is active when temperature reduction is
reduction switched on.
set The setpoint will be reduced by this value when the heater
reduction relative is switched on but the plant is at a standstill.
setpoint = setpoint entry – reduction relative
This setting is preferred for die-head gap heaters.
actual actual temperature of the heating zone
actual value
actual This is the active setpoint for the temperature regulator
setpoint on after the ramp.
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Display of the heater's regulation ratio.

actual
regul. ratio
actual The temperature difference between the setpoint and the
difference actual value.
4.13.6 Heating zone temperature enable

The extruder may only be switched on after heating is switched on and operating
temperatures have been reached.
The temperature limits (30 °C) too hot and (10 °C) too cold can be set for each
heating zone.
4.13.7 Heating zone control parameters

Separate control parameters for heating and cooling can be set for heating zones
equipped with a cooling function (blower).
Kp temperature control proportional amplification

Tn temperature control latency time
Tv temperature control retention time
4.13.7.1 Heating zone control parameter optimisation

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Control parameters can be set by way of an auto-tune function.
Attention: This function should only be implemented by experienced

personnel. The optimisation of a heating zone on the die-head may take several
hours. This function may only be performed when the plant is at a standstill.
Function: The heating zone is to be kept cooler than 100 °C. The "Auto-tune heating"
control button will start the function at the 160 °C setpoint shown above. As long as
"Auto tune" is active, this button will have a bright background. If "Auto-tune heating"
is terminated, this heating zone will be switched off and the control button
background will be dark.
The "Auto-tune cooling" function should only be performed for a hotter zone. After
successful optimisation the new kp, Tn and Tv control parameters will be calculated.
max maximum rise speed

Tu heating zone latency time
Both values are used in the calculation of control parameters.
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4.13.8 Heating zone current monitoring

Heater electric currents are measured cyclically every 10 minutes. To this end, every
10 minutes all heating zones are briefly switched off then only one of them briefly
switched on. The current measured is compared to the setpoint current minus the
difference limit. With the heater switched off, a current check is made to detect a
short circuit condition in the solid state relay.
set current setpoint
setpoint
set permissible deviation between setpoint and actual value
difference limit
actual current actual value
actual value
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4.14 Profile
4.14.1 Profile measurement parameters
See "service: profile regulation ratio: profile service: profile parameters" screen
Access and setting options depend on the vendor and type of profile measurement.
Refer to the given vendor's documentation about these settings.
4.14.1.1 Profile measurement correction factor

See "service: profile regulation ratio: profile" screen, PW Level 1
Display of the 2 Sigma value and the max, min values can be adjusted with the Boost
factor. Calculated tolerances derived from measured values are multiplied by the
boost factor entered. Therefore a boost factor of "1" displays unchanged values. The
boost factor should be used when there are differences between the displayed profile
and laboratory comparison measurements. The boost factor has no influence on
profile regulation.
4.14.2 Profile regulation offset

See "service: profile regulation ratio" screen
In this case the term "offset" refers to the positional correlation between profile
measurement and the profile actuators. In order to influence the profile at location X,
the respective position of the profile actuator must be correlated.
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For example, element 5 influences the respective position of the profile.
4.14.2.1 Profile regulation offset setting at C2 and C3

Offset is the difference between the 0° profile mea surement and profile regulation
element 1. This depends on the plant's setup and must be determined when the plant
is commissioned. This assessment is to be done in several steps:
• Preliminary setting
Offset can be coarsely set or calculated. The preliminary setting depends on the
type of profile measurement.
• Profile measurement with one's own live ring
Please place profile measurement in the turning point.
• Profile measurement in the layflat
Run take-off reversal to its right limit (as seen from above).
• Beginning at the profile measuring head, lay down one lot and note the regulation
zone where the lot is located.
• Calculate offset
number n: number of regulation locations
regulation zone X beneath the profile measurement head
offset = 360° * X / n.
• Check the offset
• In service, switch 2 heater cartridges to 100 %. A thin location must form beneath
the heater cartridges that are switched on.
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In this example the offset must be increased.

In order to check if the profile was influenced in the correct direction, a third heater
cartridge must be switched on.
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4.14.2.2 Profile regulation offset setting at C1

See "service: profile measurement" screen, PW Level 1
See "service profile measurement: ProfileControlActualValue" screen
During the plant's installation, attention should be given that the first
connecting plug on the cooling ring is located opposite profile measurement
point 0(home position).
Afterwards, an auto-positioning process must be started.
This field will display a "1" when auto-positioning has been successful.
4.14.3 Profile regulation parameters

These settings are to be interpreted as follows:

At a film thickness of 10 µm, heating will operate at 100 %. The maximum difference
between 2 adjacent actuators is 60 %.
This setting can be used for a film thickness of 180 µm. For film thicknesses >10 µm
and <180 µm, the values will be interpolated.
The profile actuators can be limited by the following options:

OFF Actuators will not be influenced at all
CUT OFF If average control value is >35 %, the
respective actuators will be limited
THICKEN If average control value is >35 %, all
actuators will be appropriately limited
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4.14.3.1 Profile regulation stability criterion parameters

Two stability criteria are taken into consideration:

1: If during stable regulation the 2Sigma value gets worse from one measurement to
the next by at least 70 %, profile control will be put on hold. Profile control will again
become regulated as soon as the new profile improves by 35 %.
2: If mean thickness changes between 2 profile measurements by more than 10 %,
profile control will be put on hold.
4.14.4 Profile regulation actuator function monitoring / current

measurement
The actuators (heater cartridges) are monitored cyclically. Every 15 minutes all
actuators are switched off and one actuator is switched on. The difference between
measured on/off currents is the current for this heating zone. If this value deviates by
more than 50 % from the setpoint, a respective alarm will be issued. These alarms
will only be displayed after all heater cartridges have been measured. Furthermore,
only a maximum of 10 such alarms will be displayed. The currently measured zone
will be displayed.
Since a routine current measurement
cycle can take several hours, there is
also an option for initiating current
measurement manually by pressing a
button.
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4.14.5 Profile history

See "service: profile history" screen
All profiles will be stored for 1 week.
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4.15 Plant stop

There are various events which can shut down the plant.
4.15.1 Web break

See "service: USB: basket" screen, PW Level 1
This operates as follows:

a sensor (ultrasonic) is located above the calibration basket to monitor if film is
present.
This sensor is activated following a preset delay [15 min.] after the extruder begins to
run. Once activated, if a no-film condition is detected for a certain time [5 s] the plant
will be shut down. This function can be turned off by setting the values to 0.
The delay time can be restarted
[15 min] by activating this control
button. The illuminated control button
signals that the web break function is
active.
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4.15.2 Defects in film composition

See "service: plant stop" screen
This function is only available if the gravimetric dosing option is installed.
Alarm Alarm Alarm Alarm

12002 12003 12102 12103
If a component is missing due to a supply shortage it can ruin the entire production
output. This can happen when gravimetric dosing reports the supply shortage or
expired fill-time but the plant continues to produce.
The screenshot above shows the given options for alarms that can lead to a
shutdown.
Alarm number Alarm text

12002 Extruder A, main component hopper fill-time expired
12003 Extruder A, main component hopper empty
12102 Extruder A, auxiliary component x, hopper fill-time expired
12103 Extruder A, auxiliary component x, hopper empty
If, despite this option, the plant should be shut down anyway, this can be set here.
The heater can be set to reduce heat following a preset time after shutdown [15min].
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4.16 Alarms
4.16.1 Alarm classification
The classification of alarms can be changed. Classification is the means by which an
alarm is assigned to the red or yellow signal lamps or to the horn. Additionally, there
are 2 free controller outputs available for driving external devices. These outputs can
be assigned to alarms as desired.
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4.16.2 Customer alarms

External alarms can also be connected as inputs to the controller. The alarm text can
be entered into this screen.
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4.17 Material database

See "service: materials" screen, PW Level 1
The material database is subdivided as follows.

Each material has its own line (database record). Various items of information are
stored in the record for each material. The individual fields are explained briefly here.
name Unique material name. This name must be unique (i.e.

occur only once) within the database.
density Material density.
This value is mandatory for use in the layer thickness
calculation.
manufacturer manufacturer name
This field can be used but is not mandatory.
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bulk density Bulk density. This value specifies the material's bulk
weight. This value is mandatory for the "residual
quantities management" function. If this value is
unknown, it can be determined by weighing a one litre
volume sample of the material. For example, if one litre
of material results in a weight of 300 g, this
corresponds to an entry value of 0.3 g/cm³.
ID material ID number
class material's classification
MFI melt flow index
V-temp processing temperature
A-temp melt on temperature
anti-block % share of anti-block
slip % share of slip
Any operator can append new material records. However, PW Level 1 is required to
change records.
When changes are made, the "Export" function should be used to back up the
material database to a data carrier.
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4.18 Supplementary functions and information
4.18.1 Back up recipes

See "service: back up recipe" screen
All information and changes made by the customer should be backed up as a matter
of security. This ensures the trouble-free replacement of parts if that should become
necessary.
Before starting the backup, insert a 1.4 MB diskette.

Start the automatic
backup.
4.18.2 Base parameters

See "service: basis parameter" screen
All information and changes made by the customer should be backed up as a matter
of security. This ensures the trouble-free replacement of parts if that should become
necessary.
Relevant parameters in every controller can be set, even by end users. When
changes are made, they should be backed up so that the trouble-free replacement of
controllers is assured.
Please proceed in the following steps.

• Select the particular controller in the upper field
(Mark this field then press the Enter key.)
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• Select a file in the right-hand field and press the "recipe load" control button.
• The filename of the loaded file will appear in the upper field.
• These parameters must be loaded into the controller.
All parameters will be transferred to the controller.
Only selected parameters will be transferred.
Other functions are also possible:

All parameters will be transferred to the
controller.
The selected recipe can be changed.

Such a change is only temporary but can
also be stored.
Only the marked value will be transferred
to the machine.
An overview of all recipes can be printed

or displayed in tabular form.
Print out the recipe
Recipes can be stored to a data media as

a backup (export) then imported again
later on whenever needed.
A recipe can be deleted.
The selected recipe will be loaded into
intermediate memory.
This controller's current parameters will
be stored in a recipe.
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4.18.3 Versions
See "service: versions" screen
Display of all plant software versions. This is of interest primarily to Kiefel.
4.18.4 Printer
See "service: Printer status" screen
Initiated printer orders are collected in a spooler loop. The printer orders which have
been collected can be deleted here. This function can be meaningfully used before
re-supplying the printer with paper to avoid large printouts.
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4.18.5 PLC
See "service: PLC" screen
Display of attached controllers.

The left half of this window shows individual controllers and the number of their
registered variables.
The right half of this window shows the chronological events with the controllers.
This is of interest primarily to Kiefel.
4.18.5.1 PLC
See "service: PLC details" screen
This is a display of controller variables and their values. This is of interest primarily to
Kiefel.
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4.18.6 Lamp-check
All illuminated pushbuttons, including the alarm signal lamps, will light up briefly.
4.18.7 Print roll report

If a roll report is to be printed automatically after every roll change then this
functionality can be switched on here.
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4.19 PC Functions
4.19.1 Touch calibration
The assignment of mouse pointer to the finger (touch) can be set. This process is
referred to as calibration.

Start the program with the key then follow its instructions.
4.19.2 Time and region settings

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The date, time and time zone can be set with the normal window's function.
To do this, please press the key then double-click on the time display in the task
bar. The Date/Time Properties window should open.
4.19.3 Emergency operation

Within a Kirion network containing multiple IPCs (industrial personal computers), data
is only stored at one location. "Data" includes, for example, recipes, trends, alarm
history, material base data, etc.
This data backup is normally done on the extruder IPC. The two IPCs normally
communicate via Ethernet. If the extruder IPC should fail, the second IPC takes over
this task automatically. The display "local" will appear.
If the plant is switched on, the second IPC will always wait for the extruder IPC. In
this case, the second IPC must be started explicitly.
• Set the focus to the Kirion logo.
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• Press the escape key.

• The Kiefel logo will be framed in red. The application will start up.
Set screen focus
Press the escape key
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The application will start up.
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5 Alarm list
All machine alarms are listed again in the table below.
In the alarm list, the character string "%1" serves as a placeholder for extruder A ... N
or winder 1 or 2.
Extruder %1, Zone %2, The measured electric current in a heating

10001 current alarm zone is out of tolerance (too great or small).
Die-head, Zone %2, current The measured electric current in a heating
10002 alarm zone is out of tolerance (too great or small).
Extruder %1, Zone %2, The heating zone is too hot.
10003 temperature too high
Die-head, Zone %2, The heating zone is too hot.
10004 temperature too high
Extruder %1, Zone %2, The heating zone is too cold.
10005 temperature too low
Die-head, Zone %2, The heating zone is too cold.
10006 temperature too low
The heating zone is switched off, but a
Extruder %1 Zone %2, current is flowing. Power will be removed from
10007 current alarm the entire heater.
The heating zone is switched off, but a
Die-head, Zone %2, short current is flowing. Power will be removed from
10008 circuit the entire heater.
Extruder %1 Zone %2, sensor The temperature sensor is interrupted.
10009 break
Die-head, Zone %2, sensor The temperature sensor is interrupted.
10010 break
Extruder %1, Zone %2, circuit
10011 is open
Die-head, Zone %2, circuit is
10012 open
Extruder %1 Zone %2, auto- Optimisation of this heating zone was faulty.
10013 tuning faulty
Die-head, Zone %2, auto- Optimisation of this heating zone was faulty.
10014 tuning faulty
When the temperature sensor has no contact
to the hot part, this monitor will prevent
Extruder %1, Zone %2, Delta continuous heating. Power will be removed
10015 Theta monitoring from the entire heater.
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When the temperature sensor has no contact

to the hot part, this monitor will prevent
Die-head, Zone %2, Delta continuous heating. Power will be removed
10016 Theta monitoring from the entire heater.
Extruder %1, Zone %2, The maximum permissible temperature has
10017 exceeded the entire heater.
Die-head, Zone %2, The maximum permissible temperature has
10018 exceeded the entire heater.
Extruder %1, speed
10020 acquisition
Monitor warning produced by proximity switch
10021 Extruder %1, no pellets in the feeder.
It is possible to connect another proximity
switch.
Extruder %1, no pellets at This other switch can be used if Kiefel is not
10022 feeder the dosing unit supplier.
Monitor fault produced by proximity switch in
10023 Extruder %1, no pellets the feeder.
If the actual temperature is below the preset

Extruder %1, Tempering unit setpoint, a warning will be generated. The
10030 %2, too cold limit is adjustable.
If the actual temperature is above the preset
Extruder %1, Tempering unit setpoint, a warning will be generated. The
10031 %2, too hot limit is adjustable.
The tempering unit reports a fault. The signal
Extruder %1, Tempering unit lamp on the tempering unit will identify the
10032 %2, fault fault.
10040 Air supply fault Frequency inverter fault report
10041 Air exhaust fault Frequency inverter fault report
10042 Cooling ring fault Frequency inverter fault report
Tempering unit's fault report;
this report is only enabled when the cooling
10043 Cooling unit, cooling ring fault ring's setpoint is >50 %
Tempering unit's fault report;
this report is only enabled when the cooling
10044 Cooling unit, supply air fault ring's setpoint is >40 %
Fault in the drive's regulator. The regulator

10050 Extruder %1, drive fault will show a specific fault number
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Extruder %1, Pressure sensor The transducer's output is a 4 to 20 mA

%2, melt pressure sensor current loop. When no current flows, this
10051 faulty alarm will be displayed
Extruder %1, Pressure sensor The preset alarm threshold has been
10052 %2, melt pressure warning exceeded
Extruder %1, Pressure sensor The preset alarm threshold has been
10053 %2, melt pressure fault exceeded. The extruder will be switched off.
Extruder %1, difference The preset pressure difference is too great.
10054 pressure too great The sieve should be changed.
Extruder %1, heater switched
10060 off#
10061 Die-head heater switched off
10101 Hopper %1, is empty The lower limit switch reports no pellets.
The supply blower's motor protection switch
10102 Supply blower %1, fault has activated.
This alarm is issued if the hopper is full but
the flap does not swing down after this fill
10103 Hopper %1, supply alarm cycle.
10104 Supply valve not in position no longer used
This alarm is specific to the "residual
quantities management" option and indicates
Hopper %1, auto filling has the filling of this hopper has been switched
10105 switched off off.
10201 Basket height fault The motor protection switch has triggered.
10202 Basket diameter fault The motor protection switch has triggered.
Film is not detected. After a brief delay, the
10203 Warning, no film plant will be shut down.
Film is not detected. The plant has been shut
10204 Fault, no film down.
No bus connection to the calibration basket's
10205 USB coupling is defective local controller.
The maximum roll diameter has been
exceeded in the pre-winding station. The
winder will be turned off for reasons of safety.
Winder %1, maximum roll Determine why roll change is taking longer
diameter attained in the pivot than permissible roll growth in the pre-winding
11000 arm. station.
The roll diameter has reached a critical value.
Winder %1, magazine load If roll diameter increases further, a shaft
11001 shaft timeout cannot be inserted.
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The roll diameter has reached a critical value.
Winder %1, roll change: no If roll diameter increases further, a shaft
11002 shaft in the magazine cannot be inserted.
Winder %1, roll change: The deposit location (pallet, roll cart, ...)
11003 deposit location not ready does not return a ready (free) signal.
The roll's diameter has exceeded its
maximum value.
Every winder is designed for a particular roll
diameter. Once this diameter has been
reached, a roll change will be initiated
Winder %1, roll diameter (automatic mode) or requested (manual
greater than maximum mode). If this is not possible, the winder will
11004 diameter. be halted.
Winder %1, shaft magazine
Winder %1, shaft did not
11006 arrive in transfer position The limit switch was not activated.
Winder %1, shaft magazine The shaft positioner was not in its base
11007 not in base position position when the roll change started.
Winder %1, winder direction
reversal could not be
11008 activated nn
The shaft positioner moved beyond the
initiator for the transfer position. The roll
Winder %1, shaft positioner change function cannot be accomplished
11009 moved too far reliably.
Winder %1, pivot arm forward
Winder %1, pivot arm
backward motor protection
Winder %1, knife not in base The crosscut knife was not in its base position
11012 position when the roll change started.
Winder %1, shaft accelerator
Winder %1, shaft accelerator The shaft accelerator is not in its base
11014 not retracted position.
Winder %1, lift crane motor
Winder %1, deposit location The deposit location is currently in use by the
11016 not free other winder.
178 / 215
G030
Winder %1, knife bar not in The knife bar was not in its base position
Winder %1, pivot arm not in The pivot arm was not in its base position
Winder %1, slitting roller in
wrong position (rotation
11019 reversal) The limit switch was not activated.
Winder %1, hydraulic pump
motor protection switch / fault The motor is overloaded, blocked or there is a
11020 in frequency inverter fault in the frequency inverter.
Winder %1, hydraulic oil The hydraulic oil is too hot. Please check the
11021 overtemperature oil level and observe the warning notice.
Winder %1, load arm: fault The correct values could not be transferred to
11022 during parameter transfer the frequency inverter.
Winder %1, invalid command
11023 code software program error
11024 Winder %1, safety bumper The safety bumper was activated.
Winder %1, safety zone
11025 overrun The floor mat was activated.
The load arm's angle transducer provides no
11026 Winder %1, encoder fault valid values.
Winder %1, load arm: Em. An Emergency OFF switch or Emergency
Winder %1, oil pressure too
11028 low The hydraulic pressure is too low.
Winder %1, left load arm not The left load arm is blocked or the limit switch
11029 extended to the right was not activated.
11030 extended to the left was not activated.
11031 retracted to the right was not activated.
11032 retracted to the left was not activated.
Winder %1, rotary winder not The rotary winder is not in the correct position
11033 in position or the limit switch was not activated.
11034 supports not retracted limit switch was not activated.
11035 supports not swung in limit switch was not activated.
11036 supports not swung out limit switch was not activated.
179 / 215
G030
Winder %1, load arm bolts The load arm bolts are blocked or the limit
11037 not retracted switch was not activated.
Winder %1, load arm bolts The load arm bolts are blocked or the limit
11038 not extended switch was not activated.
Winder %1, the hydraulic
pump's frequency inverter
11040 motor overtemp. The motor is overloaded.
Winder %1, primary nip: Em. An Emergency OFF switch or Emergency
Winder %1, primary nip: edge
strip suction motor protection
terminal box supply circuit
11043 breaker The fuse has blown.
Winder %1, primary nip: fault
Winder %1, primary nip: FI
longitudinal knife oscillation
Winder %1, primary nip: no
treatment cannot be switched
11052 on The pre-treatment unit cannot be switched on.
Winder %1, primary nip: fault The correct values could not be transferred to
180 / 215
G030
Winder %1, separation roller: An Emergency OFF switch or Emergency

fault during parameter The correct values could not be transferred to
11076 transfer the frequency inverter.
Winder %1, trim nip: motor
Winder %1, trim nip: Em. stop An Emergency OFF switch or Emergency
11081 activated OFF pull-cord has been activated.
Winder %1, trim nip: fault in
Winder %1, trim nip: FI
Winder %1, trim nip: no pull
11089 tension setpoint The setpoint must be increased.
Winder %1, trim nip: fault The correct values could not be transferred to
Winder %1, trim nip: coupling There is no bus connection between the
11099 could not be initialised controller and the frequency inverter.
Winder %1, trim nip,
11100 spreader: motor overtemp. The motor is overloaded or blocked.
Winder %1, trim nip, An Emergency OFF switch or Emergency
11101 spreader: Em. stop activated OFF pull-cord has been activated.
11102 2: motor overtemp. The motor is overloaded or blocked.
11104 spreader: fault in FI The frequency inverter reports a fault.
11105 spreader: FI overtemperature The frequency inverter is too hot.
11108 2: fault in FI The frequency inverter reports a fault.
11109 2: FI overtemperature The frequency inverter is too hot.
181 / 215
G030
Winder %1, trim nip: spreader

2: fault during parameter The correct values could not be transferred to
Winder %1, trim nip:
spreader: fault during There is no bus connection between the
11116 parameter transfer controller and the frequency inverter.
2: coupling could not be The correct values could not be transferred to
11118 initialised the frequency inverter.
spreader: coupling could not There is no bus connection between the
11119 be initialised controller and the frequency inverter.

Winder %1, winder drum: An Emergency OFF switch or Emergency
11161 pull-cord switch activated OFF pull-cord has been activated.
edge strip suction motor
Winder %1, winder drum: FI
Winder %1, winder drum: film The film has wound itself around the drum or
11166 wound around drum the light barrier is incorrectly aligned.
The winder drum has been pressed back for
Winder %1, winder drum: more than 1 minute. CLP air pressure is too
11167 drum pressed to the rear low.
11168 static winding aid defective The high voltage generator reports a fault.
Winder %1, winder drum: no
treatment cannot be switched
11172 on The pre-treatment unit cannot be switched on.
182 / 215
G030

fault during parameter The correct values could not be transferred to
Winder %1, spreader: motor
Winder %1, spreader: Em. An Emergency OFF switch or Emergency
Winder %1, spreader: fault in
Winder %1, spreader: FI
Winder %1, spreader: fault The correct values could not be transferred to
Winder %1, spreader:
Winder %1, central drive: Em. An Emergency OFF switch or Emergency
Winder %1, central drive: fault
Winder %1, central drive: FI
Winder %1, central drive: fans
11206 monitor The motor is overloaded or blocked.
coupling did not open within The central drive's coupling could not be
coupling did not close within The central drive's coupling could not be
Winder %1, central drive: no
Winder %1, central drive: fault The correct values could not be transferred to
183 / 215
G030

11220 drive: motor overtemp. The motor is overloaded or blocked.
Winder %1, double centre An Emergency OFF switch or Emergency
11221 drive: Em. stop activated OFF pull-cord has been activated.
11224 drive: fault in FI The frequency inverter reports a fault.
11225 drive: FI overtemperature The frequency inverter is too hot.
drive: fault during parameter The correct values could not be transferred to
drive: coupling could not be There is no bus connection between the
11240 cabinet fans monitor The motor is overloaded or blocked.
11241 cabinet temperature monitor Switchgear cabinet temperature is too high.
Winder %1, safety relay
11242 monitor The controller is not switched on.
The controller's battery must be replaced. The
Winder %1, PLC battery system should remain continuously powered
11243 monitor on.
Winder %1, air pressure
11244 monitor < 4 bar The air pressure is too low or missing.
Winder %1, winder supply The frequency inverter's supply unit is
11245 unit monitor defective.
Winder %1, fault while The display's built-in CAN interface could not
11246 initialising the CAN interface be initialised.
Winder %1, no 230 V line
11247 feed The supply voltage is missing.
Winder %1, knife's
longitudinal oscillation motor
Winder %1, knife's
transversal oscillation motor
Winder %1, vacuum pump
Winder %1, switchgear An Emergency OFF switch or Emergency
11251 cabinet Em. stop activated OFF pull-cord has been activated.
184 / 215
G030
Winder %1, display screen An Emergency OFF switch or Emergency

11253 the options not found software program error
11254 initial values not found software program error
11255 the version not found software program error
11256 the alarm mode not found software program error
The coupling between 2 controllers is
11257 Winder %1, CAN I/O error interrupted
Winder %1, no supply feed to
11258 transformer
11259 Winder %1, UPS reports fault
11261 fault in frequency inverter The frequency inverter reports a fault.
11262 fuse in frequency inverter The fuse has blown.
Winder %1, shaft extractor: There is a conflict between shaft prisms of
11263 wrong prism selected winding shafts
11264 no shaft found The limit switch was not activated.
11266 reset mode active Emergency mode is activated.
11267 not in base position The limit switch was not activated.
11268 ventilation fault The limit switch was not activated.
11269 prisms not open The limit switch was not activated.
Winder %1, shaft extractor: The coupling between 2 controllers is
11270 CAN I/O error interrupted
data module with initial values
11271 not found software program error
11272 ventilation valve not retracted The limit switch was not activated.
185 / 215
G030

shaft supports motor
11276 shaft support Em. stop OFF pull-cord has been activated.
shaft support not in base
11278 shaft support not on shaft The limit switch was not activated.
tube cylinder not in base
11280 Winder %1, roll cart: fuse The fuse has blown.
Winder %1, roll cart: motor
Winder %1, roll cart: safety
11282 bumper The roll cart is standing at an obstacle.
Winder %1, roll cart: not in
11283 base position The limit switch was not activated.
Winder %1, roll cart: flap not
11284 in base position The limit switch was not activated.
11285 Winder %1, service mode: Service mode has been activated.
Winder %1, roll cart: pallet
11286 sensor not activated The limit switch was not activated.
Winder %1, roll cart: hydraulic
11287 pump MPS The motor is overloaded or blocked.
11288 table arrived at top The limit switch was not activated.
11289 table not in base position The limit switch was not activated.
Winder %1, roll cart: CAN I/O The bus connection between 2 controllers is
11290 error interrupted.
Winder %1, interm. nip: motor
Winder %1, interm. nip: Em. An Emergency OFF switch or Emergency
Winder %1, interm. nip: fault
Winder %1, interm. nip: FI
186 / 215
G030
Winder %1, interm. nip: fault The correct values could not be transferred to
Winder %1, interm. nip:
11320 train: motor overtemp. The motor is overloaded or blocked.
Winder %1, cooling roller An Emergency OFF switch or Emergency
11321 train: Em. stop activated OFF pull-cord has been activated.
11324 train: fault in FI The frequency inverter reports a fault.
11325 train: FI overtemperature The frequency inverter is too hot.
train: coupling could not be There is no bus connection between the
Winder %1, CAN I/O fault The bus connection between 2 controllers is
11340 report interrupted.
Winder %1, coupling to roll The bus connection between 2 controllers is
11341 cart interrupted interrupted.
11342 Winder %1, local I/O error The controller reports a fault.
Winder %1, coupling to take- The bus connection between 2 controllers is
11343 off interrupted interrupted.
11345 parameters loaded Standard base parameters have been loaded.
Winder %1, coupling to other The bus connection between 2 controllers is
11346 winder interrupted interrupted.
Winder %1, frequency
11347 inverter parameters not found software program error
Winder %1, "Deposit point The operator has activated the "Ignore
11348 occupied" message ignored deposit location" function.
11349 Winder %1, version conflict software program error
Winder %1, motor protection
11351 switch (collective fault) A motor is overloaded or blocked.
187 / 215
G030


Extruder A, main component measurement range.
weigher measurement out of Weigher cell: defective or incorrectly
12000 limits attached, check supply voltage
Extruder A, main component range.
speed measurement out of Speed: sensor defective, check supply
12001 limits voltage
prescribed time.
Check suction conveyor, check supply air to
slide valve.
open/close switch.
Check material fill level in the hopper, the use
Extruder A, main component of materials having strongly varying bulk
12002 hopper fill-time expired density can cause overflow.
Suction feeding insufficient.
Put the Man / Auto switch on PC5K in manual
position.
Extruder A, main component Compressed air pressure too low.
12003 hopper empty No valid weighing signal.
"AUTO" position.
Automatic filling of the weighing hopper is not
Extruder A, main component possible.
12004 hopper switch not in Auto Weighing hopper can run empty.
188 / 215
G030
Extruder A, main component Weighing hopper is almost empty.

throughput measurement Material deficiency in the supply container.
12005 invalid Worm speed acquisition is instable.
The edge strip extruder was switched off
Extruder A, main component during production.
throughput measurement, Edge strip calculations are suspended.
12006 edge strips torn off Extruder regulation switches off.
Extruder A, main component Material deficiency in the weighing hopper.
throughput regulation, no Throughput measurement no longer possible.
12007 valid values Worm speed instable.
Speed was manually adjusted during
Extruder A, main component automatic mode.
throughput regulation, Check speed acquisition (speed pulse
12008 deviation too large generator, cable, etc).
Emergency OFF chain was activated.
Web break.
The digital input signal "Extruder ON" was
Extruder A, main component deactivated.
throughput regulation, All slide valves remain closed, all measuring
12009 extruder switched off and regulating functions are suspended.
Extruder A, main component Motor run up to maximum speed.
throughput regulation, Check production data, reduce machine
12010 setpoint not reached performance if necessary
Setpoint/actual value deviation is greater than
10 percent.
Extruder throughput instable, see pressure or
flow display.
Compressed air pressure for the slide valve
Extruder A, main component too low.
speed regulation, regulation Material fill level in the hopper too high.
12011 out of tolerance Faulty cable connections.
Extruder A, main component Speed measurement value was underrun or
speed regulation, overrun.
measurement value out of Check speed acquisition (speed pulse
12012 limits generator, cable, etc).
12013
12014
189 / 215
G030
This value was deemed invalid after entry of a

Extruder A, main component new setpoint.
invalid setpoints for product Check setpoints, perhaps a decimal point
12015 conversion position mistake was made.
Extruder A, main component
12016 measurement instable

Extruder A, auxiliary measurement range.
component x, weigher Weigher cell: defective or incorrectly
12100 measurement out of limits attached, check supply voltage
Extruder A, auxiliary range.
component x, speed Speed: sensor defective, check supply
12101 measurement out of limits voltage.
prescribed time.
Check suction conveyor, check supply air to
slide valve.
open/close switch.
Extruder A, auxiliary Check material fill level in the hopper, the use
component x, hopper fill-time of materials having strongly varying bulk
12102 expired density can lead to over-filling.
Not enough suction feed power.
The Man / Auto switch on PC5K is in manual
position.
Extruder A, auxiliary Compressed air pressure too low.
12103 component x, hopper empty No valid weighing signal.
"AUTO" position.
Extruder A, auxiliary Automatic filling of the weighing hopper is not
component x, hopper switch possible.
12104 not in Auto Weighing hopper can run empty.
Extruder A, auxiliary Weighing hopper is almost empty.
component x, throughput Material deficiency in the supply container.
12105 measurement invalid Worm speed acquisition is instable.
Extruder A, auxiliary The edge strip extruder was switched off
component x, throughput during production.
measurement, edge strips Edge strip calculations are suspended.
12106 torn off Extruder regulation switches off.
190 / 215
G030
Extruder A, auxiliary Material deficiency in the weighing hopper.

component x, throughput Throughput measurement no longer possible.
12107 regulation, no valid values Worm speed instable.
Speed was manually adjusted during
Extruder A, auxiliary automatic mode.
component x, throughput Check speed acquisition (speed pulse
12108 regulation, deviation too large generator, cable, etc).
Emergency OFF chain was activated.
Web break.
Extruder A, auxiliary The digital input signal "Extruder ON" was
component x, throughput deactivated.
regulation, extruder switched All slide valves remain closed, all measuring
12109 off and regulating functions are suspended.
component x, throughput Motor run up to maximum speed.
regulation, setpoint not Check production data, reduce machine
12110 reached performance if necessary
Setpoint/actual value deviation is greater than
10 percent.
Extruder throughput instable, see pressure or
flow display.
Extruder A, auxiliary Compressed air pressure for the slide valve
component x, speed too low.
regulation, regulation out of Material fill level in the hopper too high.
12111 tolerance Faulty cable connections.
Extruder A, auxiliary Speed measurement value was underrun or
component x, speed overrun.
regulation, measurement Check speed acquisition (speed pulse
12112 value out of limits generator, cable, etc).
The internally calculated setpoint for
Extruder A, auxiliary regulation (e.g. dosing tracking) for a
component x, speed deactivated conversion lies outside the valid
regulation, setpoint out of range.
12113 limits Change the dosing worm.
191 / 215
G030
The motor's electronic overload protection

has triggered.
Check for a material jam.
Extruder A, auxiliary Dosing worm feed capacity exceeded.
component x, speed Problematic material properties, a larger
regulation, motor overloaded: cylinder may be necessary.
12114 wrong worm Check the dosing motor's carbon brushes.
Extruder A, auxiliary At least one setpoint was deemed invalid after
component x, invalid activation of the "conversion" control button.
setpoints for product Check setpoints, perhaps a decimal point
12115 conversion position mistake was made.
component x, measurement
12116 instable
Take-off, weigher
12200 measurement out of limits
Take-off, speed measurement
12201 out of limits
Take-off, hopper fill-time
12202 expired
12203 Take-off, hopper empty
Take-off, hopper switch not in
12204 auto
Take-off, throughput
12205 measurement invalid
measurement, edge strips
12206 break
12207 regulation, no valid values
12208 regulation deviation too great
regulation, extruder switched
12209 off
regulation, setpoint not
12210 reached
Take-off, speed regulation,
12211 deviation too great
Take-off, speed regulation,
12212 measured value out of limits
192 / 215
G030
Take-off, speed regulation, bit

12213 13
Take-off, speed regulation, bit
12214 14
Take-off, product conversion,
12215 invalid setpoints
Extruder %1, performance
limit reached. Automatic If an overload occurs while the extruder motor
12250 mode was switched off is accelerating, acceleration will be stopped.
The plant was shut down due to a
component's material deficiency. See setting
12255 Plant stop on service screen "plant stop".
The thickness setpoint is out of its limits with
regulation switched on.
12300 Thickness outside limits The alarm limits are defined in the trend.
If the profile is much worse with activated
control as the last profile then control will be
put on hold.
If the unregulated profile is better, profile
Profile measurement is control will be switched on again.
instable, profile control will be The limit for this can be set in the "service"
If film thickness changes during a profile
measurement cycle, profile control will be
Film thickness is instable, suspended.
profile control will be The limit for this can be set in the "service"
Alarms will be registered by the system but
the acoustic or visual indicator at the machine
will not be activated. Switching alarms on and
off is done by the operator with a respective
Batch extruder %1, alarms
control button on the alarm screen.
12500 SWITCHED OFF
This alarm notifies the operator that the
system has started and is loading the data
that was stored the last time the STORE TO
ROM control button was activated. This
display terminates when alarms are reset. If
this alarm occurs, the proper functionality of
the program must be checked and the
Batch extruder %1, no manufacturer's customer service department
12501 backup data notified.
193 / 215
G030
This indication is analogous to a previous one

but is in relationship to the external GEC
control module which controls the take-off and
extruder (if this controller is configured into
Batch extruder %1, external
the system).
12502 TIMEOUT remote I/O CP 430
This is a display arising from missing CAN
communication between the PLC and I/O
Batch extruder %1, external control modules responsible for feeding the
12503 TIMEOUT remote I/O X67#1 dosing unit.
The dosing unit's minimum fill level sensor is
exposed at the surface. Check if the pellet
Batch extruder %1, MIN fill sucker is properly delivering material to the
12509 level, dosing unit #1 dosing unit.
194 / 215
G030

The dosing unit's actual value lies outside the
preset TOLERANCE threshold. Possible
causes are: pellets have blocked the slide
valve, water or dirt in the pneumatic line, no
Batch extruder %1, dosing material available, compressed air outage,
unit #1 OUTSIDE tolerance defective magnet valve, problems with the
12515 range piston.
12516 range piston.
12517 range piston.
12518 range piston.
195 / 215
G030

12519 range piston.
12520 range piston.
Material is not available in the dosing unit's
hopper, the hopper is clogged, or there is not
Batch extruder %1, enough material at this slide valve to uphold
12521 component #1, missing the intended throughput.
196 / 215
G030
This alarm is generated frequently in

transition phases and is caused by a
changeover to material with a different
pourability. During normal processing this
alarm indicates uneven material dosing,
typically caused either by lack of material or
Batch extruder %1, irregular by material with bad pourability.
12527 flow, dosing unit #1
197 / 215
G030

A material flow has developed that deviates
too much from the intended flow. When this
Batch extruder %1, dosing compressed air outage, defective magnet
12533 unit #1, NOT OK valve, problems with the piston.
198 / 215
G030

Batch Extruder %1, trim Material in the trim hopper has reached its
12539 hopper full highest - minimum fill level.
Batch Extruder %1, trim Material in the trim hopper has reached its
12540 hopper empty highest - minimum fill level.
Batch extruder %1, mixer
12541 cover open
Material in the mixing hopper has reached the
value set with the parameter MIXER
MINIMUM FILL LEVEL (kg). A check must be
made to see: if the dosing system is on RUN,
if material is lacking in the dosing unit's
hoppers, and if the dosing cycle is perhaps
too long; in this last case, extrusion
throughput must be reduced or a check made
Batch extruder %1, mixer MIN to see if the % setpoints for dosing are too
12542 fill level high.
Batch Extruder %1, mixer The mixer motor is locked out due to
12543 thermal protection overheating.
The mixer did not fill itself after the batch
hopper was emptied. Check if the batch
Batch extruder %1, mixer not hopper's slide valve has opened properly and
12544 filled if material is missing in the hoppers.
199 / 215
G030
The weight of the weigher hopper has

reached the kg value preset in the parameter
MAXIMUM BATCH WEIGHT (kg). This alarm
is typical of problems with the pneumatic lines
(water present, pressure fluctuations) or for
mechanical problems (pellets that slow down
the slide valve). If no problems are present,
one can increase the value of the
Batch Extruder %1, batch
aforementioned parameter.
12545 weigher full
The batch discharge valve did not open within
the BATCH DISCHARGE TIMEOUT (S)
period. The cause of this alarm is either
inaccurate calibration of weigher cells, an
excessively large batch with discharge level
set too high, or a mechanical or pneumatic
Batch extruder %1, batch problem at the batch weigher (piston, slide
12546 weigher NOT emptied valve, etc).
The hopper's slide valve did not close again
after discharging the batch hopper. The cause
of this alarm is either an inaccurate calibration
of the weigher cells, an excessively large
batch with discharge level set too high, or a
Batch extruder %1, weigher mechanical or pneumatic problem at the
open, dosing cannot take hopper (piston, slide valve, etc).
12547 place
The alarm "weigher closed, mixer not filled"
will be issued when at least one dosing unit
has the status OPERATING, the weigher has
the status CLOSED and global status RUN is
true. If the operator resets this alarm, but the
alarm condition persists, then the alarm will
be issued again after the blanking period
expires. In this case, the machine will perform
Batch extruder %1, weigher dosing but the mixer will not fill even though it
12548 closed, mixer not filled has a command signal.
The alarm "dosing # in STOP status, dosing >
0" will be issued for any dosing unit with the
Batch extruder %1, dosing blanking period expires. In this situation the
unit #1, STOP at SW% machine switches dosing tolerance control
12549 dosing > 0 off.
200 / 215
G030

201 / 215
G030
Batch extruder %1, dosing

unit #1 STOP with OPEN
12555 valve
12556 valve
12557 valve
12558 valve
12559 valve
12560 valve
Batch extruder %1, flow
12561 control valve CLOSED
Batch extruder %1, mixer The material fill level lies under the mixer
12562 hopper MIN fill level hopper's minimum fill level sensor.
Indicates the worm mounted on the extruder
is not capable of feeding demanded
throughput or the dosing unit mounted on the
extruder cannot handle the preset
Batch extruder %1,
percentages demanded for throughput.
12563 throughput NOT realised
The extruder's ACTUAL % value in kg/h is
outside the TOLERANCE threshold. Check to
see if pellet feeding is operating properly, if
Batch extruder %1, extruder there are mechanical obstacles on the
throughput OUTSIDE weigher cells, if the filter is clogged or if the
12564 tolerance range feeding of trim is irregular.
The extruder is running faster than intended
Batch extruder %1, reduced to keep up with the preset throughput. Check
throughput / excessive for possible filter clogging.
12565 extruder speed
202 / 215
G030
The trim has torn off. (A parameter is only

present if the system is set up to control
further usage of trim in the line.) Check to see
why the customer-supplied contact on the
dosing unit is open (trim breakage, cable
pulled off, etc).
12566 Batch Extruder %1, trim break
The ACTUAL % value for take-off speed lies
outside the preset TOLERANCE threshold.
This alarm is generated when, despite a
command sent out, take-off speed does not
Batch extruder %1, take-off change accordingly. The problem is usually to
speed OUTSIDE tolerance be found in the take-off's control unit.
12567 range
The ACTUAL % value g/m lies outside the
preset TOLERANCE threshold. This alarm
typically occurs at a sudden change of
throughput, i.e. in conjunction with the alarm
Batch extruder %1, thickness "Extruder out of Tol.", or when a change of
/ metre weight OUTSIDE line speed takes place due to mechanical or
12568 tolerance range electrical take-off problems.
Locks up the entire plant, triggered by an
activated Emergency OFF button. The
Emergency OFF function is only activated
Batch extruder %1, when a connection is made to the provided
Emergency OFF button terminal board in the electrical switchgear
12569 activated box.
In the console's ORDER screen there is a
parameter for "Order quantity" in which the
total quantity to be produced is established.
When counter 1 exceeds this preset value,
this alarm will be issued. The alarm will occur
again after it has been reset if the situation
continues to be true. This control is disabled
Batch extruder %1, lot end when the parameter value is preset to zero.
12570 (kg)
Pump motor locked out due to overheating.
This overheat condition can be caused by a
clogged suction filter or discharge filter (which
are to be cleaned at regular intervals), by
Batch Extruder %1, suction material clogging the suction line or by a
12571 pump thermal protection problem with the suction pump.
203 / 215
G030
Pneumatic feeding of station no. # has

exceeded the preset time. The possible
Batch extruder %1, dosing maximum allocated time by 10 ... 20 % (see
12572 unit #1 feed blocked configuration).
204 / 215
G030

despite sufficient material supply into the
plant, the operator can increase the maximum
allocated time by 10 ... 20 % (see
parameterisation).

12576 unit #5 feed blocked
Indicates that the calibration procedure for the
dosing controller's weigher was not
concluded. This problem occurs when the cell
does not detect any significant difference
between calibration at empty and sample
Batch extruder %1, weigher weight (distance between "raw values" <
12578 cell (weigher) not calibrated 250 000).
Indicates the calibration procedure for the
mixer was not concluded. This problem
occurs when the cell does not detect any
significant difference between calibration at
Batch extruder %1, weigher empty and sample weight (distance between
12579 cell (mixer) not calibrated "raw values" < 250 000).
Batch Extruder %1, PLC
12580 TIMEOUT, layer A
205 / 215
G030
Indicates there are communication problems

between PLCs; in particular (M#A: PLC
timeout PLC layer #C) indicates the PLC
which controls layer A has communication
problems with layer #C. Therefore the
reference value of the PLC with a
communications blockage is not to be sought
at the extruder specified by the coded
Batch Extruder %1, PLC description (M#A) but rather at the one
12581 TIMEOUT, layer B specified in the alarm's description line.
12582 TIMEOUT, layer C specified in the alarm's description line.
12583 TIMEOUT, layer D specified in the alarm's description line.
12584 TIMEOUT, layer E specified in the alarm's description line.
206 / 215
G030

12585 TIMEOUT, layer F specified in the alarm's description line.
12586 TIMEOUT, layer G specified in the alarm's description line.
12587 TIMEOUT, layer H specified in the alarm's description line.
12588 TIMEOUT, layer I specified in the alarm's description line.
207 / 215
G030

Batch extruder %1, I/O description (M#A) but rather at the one
12589 initialisation not OK specified in the alarm's description line.
Heater cartridge %1, faulty / The heater cartridge's current consumption is

13500 too much current too high.
Heater cartridge %1, wire A heater cartridge's current consumption is
13501 break / too little current too small or the electric circuit is interrupted.
Heater cartridge %1, short
13502 circuit The solid state relay is defective.
13503 components faulty components and controller.
Profile measurement coupling No communication between profile
13504 interrupted measurement and controller.
The alarm limits set for profile control have
been exceeded when profile control was
active. Limits are set on the 2Sigma screen of
13505 2Sigma outside limits "trend".
13506 components 2 faulty components and controller.
Profile measurement: profile
13600 tolerance too poor see Plast Control profile control C1
Profile measurement:
13601 sum/profile tolerance too poor see Plast Control profile control C1
13602 too instable to control see Plast Control profile control C1
Profile measurement: reversal
13603 too fast/instable see Plast Control profile control C1
Profile measurement: cooling
13604 ring elements still in action see Plast Control profile control C1
13605 ring, no voltage see Plast Control profile control C1
13606 ring, overtemperature see Plast Control profile control C1
208 / 215
G030
Profile measurement: no
13607 communication see Plast Control profile control C1
13608 elements not in position see Plast Control profile control C1
13609 measurement standstill see Plast Control profile control C1
endbub/measuring position
13650 not reached see Plast Control profile measurement
Profile measurement: end
13651 home position not reached see Plast Control profile measurement
Profile measurement: film
13652 bubble too small see Plast Control profile measurement
Profile measurement: film
13653 bubble too big see Plast Control profile measurement
measurement values from C
13654 head see Plast Control profile measurement
13655 temperature C head failed see Plast Control profile measurement
Profile measurement: motor
13656 does not turn see Plast Control profile measurement
Profile measurement: bubble
13657 scanning impressed see Plast Control profile measurement
Profile measurement: bubble
13658 scanning failed see Plast Control profile measurement
Profile measurement: C head
13659 too hot see Plast Control profile measurement
13660 dirty see Plast Control profile measurement
13661 frequency too low see Plast Control profile measurement
13662 frequency instable see Plast Control profile measurement
Profile measurement: time
13663 initialization expired see Plast Control profile measurement
Profile measurement: left limit
13664 switch / tooth counting failed see Plast Control profile measurement
Profile measurement: right
limit switch / tooth counting
13665 failed see Plast Control profile measurement
209 / 215
G030
Profile measurement: tooth

13666 counting failed see Plast Control profile measurement
Profile measurement: tooth
13667 counting instable see Plast Control profile measurement
Profile measurement: max
13668 time rot. right expired see Plast Control profile measurement
Profile measurement: max
13669 time rot. left expired see Plast Control profile measurement
Profile measurement: EOS
13670 not found see Plast Control profile measurement
13671 too old see Plast Control profile measurement
measurement error
(measuring frequency too
13672 low) see Kündig profile measurement
measurement error
(measuring frequency too
13673 high) see Kündig profile measurement
measurement error
13674 (plausibility check) see Kündig profile measurement
Profile measurement: zeroing
distance too short (film bubble
13675 too large) see Kündig profile measurement
13676 telescoping drive defective see Kündig profile measurement
measurement error
(frequency during zeroing too
13677 low) see Kündig profile measurement
measurement error
(frequency during zeroing too
13678 high) see Kündig profile measurement
measuring electronics
13679 defective (power supply) see Kündig profile measurement
measuring frequency missing
(measuring electronics or
13680 data cable defective) see Kündig profile measurement
210 / 215
G030
Profile measurement: rotation

13681 signal error see Kündig profile measurement
minimum rotation time
13682 exceeded (rotation still active) see Kündig profile measurement
maximum rotation time
13683 exceeded (rotation stopped) see Kündig profile measurement
telescope arm retracted
because front limit switch
reached (film bubble torn off
13684 or too small) see Kündig profile measurement
communication with control
13685 system see Kündig profile measurement
Profile control must not be switched on. The
cause may be that the cooling ring blower is
13686 No profile control enable not running.
13687 Profile control switched off
Width measurement coupling
14000 interrupted no bus connection
Width setpoint and actual value, difference
too great.
14001 Width out of limits Alarm limit will be switched on in trend.
Width regulator has been If basket diameter is adjusted manually, width
14002 deactivated regulation will be deactivated
Width measurement sled, left:
14003 no measurement values
measurement value out of
14004 limits
14005 limit switch triggered
14006 test and EOS active
14007 cart does not move
14008 film sensor defective
14009 film too wide
211 / 215
G030

14010 no film
no communication with width
14011 node
14012 reserved
14013 right: no measurement values
right: measurement value out
14014 of limits
14015 right: limit switch triggered
14016 right: test and EOS active
14017 right: cart does not move
14018 right: film sensor defective
14019 right: film too wide
14020 right: no film
right: no communication with
14021 width node
Width regulation cannot be If net width <> gross width, width regulation
activated because gusseting will be deactivated
14022 is active
When net width from order management is
14023 Net width too small less than gross width by at least 120 mm.
Motor protection switch in
15001 take-off cabinet triggered
Fault in one of the take-off
15002 drives Drive regulator fault
Take-off, tempering unit %1
15003 too cold
Take-off, tempering unit %1
15004 too hot
Take-off, tempering unit %1,
15005 fault Tempering unit fault report
212 / 215
G030
Take-off, turning bar blocking

15006 open
The rotation angle is determined by counting
teeth on the reversal gear. If the count of
Take-off rotation tooth count teeth within a reversal of 360° is too high or
15007 faulty low, this alarm will be issued
The basket's position to the film bubble is
electrically measured with a mechanical feeler
Auxiliary basket: actual value arm. If the measured value is too small, this
15020 too small alarm will be issued
The basket's position to the film bubble is
electrically measured with a mechanical feeler
Auxiliary basket: actual value arm. If the measured value is too large, this
15021 too large alarm will be issued
When automatic mode is active the auxiliary
Auxiliary basket: automatic basket can move to its minimum or maximum
mode terminated by limit diameter. When this happens, automatic
15022 switch. mode is deactivated.
15100 Pre-treatment fault
PLC %1, data module version
19000 number not present
PLC %1, data module version
19001 number not readable
PLC %1, data module
19002 configuration not present
PLC %1, data module
19003 configuration not readable
The controller's battery must be replaced. The
system should remain continuously powered
19004 PLC %1, battery discharged on.
PLC %1, input to CAN node This controller has no bus connection.
19005 missing This controller is switched off or defective.
PLC %1, input to CAN node, The PLC reports an error code. This error
19006 error: %2 Add: %3 code can be looked up in the B&R handbook.
PLC %1, pellet supply CAN Fault in the CAN bus connection.
19007 node missing
PLC %1, pellet supply CAN The PLC reports an error code. This error
19008 node, error: %2 Add: %3 code can be looked up in the B&R handbook.
This controller has no bus connection.

19010 PLC %1, CAN coupling fault This controller is switched off or defective.
213 / 215
G030

19018 CAN coupling to panel fault This controller is switched off or defective.

19019 CAN coupling to panel 2 fault This controller is switched off or defective.
PLC %1, CAN coupling to This controller has no bus connection.

19021 gravimetric fault This controller is switched off or defective.
PLC %1, 2nd pellet supply Fault in the CAN bus connection.
19030 CAN node missing
PLC %1, 2nd pellet supply The PLC reports an error code. This error
19031 CAN node, error: %2 Add: %3 code can be looked up in the B&R handbook.
PLC %1, 3rd pellet supply Fault in the CAN bus connection.
19032 CAN node missing
PLC %1, 3rd pellet supply The PLC reports an error code. This error
19033 CAN node, error: %2 Add: %3 code can be looked up in the B&R handbook.
PLC %1, USB motor, no data The positioning signal on the CAN bus is
19035 over CAN bus missing.
PLC %1, USB motor, check The PLC control module for the USB flap
19036 PLC module motor is defective.
PLC %1, USB motor, wrong
19037 data module The wrong module has been inserted
PLC %1, check temperature The temperature measurement card is
19038 module defective.
PLC %1, temperature module The temperature measurement card is
19039 fault defective.
19040 PLC %1, module fault A control module is defective.
Operating column 1: Em. stop
19100 activated
Operating column 2: Em. stop
19101 activated
19102 Take-off: Em. stop activated
No connection to die-head
19400 station no bus connection
No connection to Extruder %1
No connection to take-off
214 / 215
G030
No connection to Winder %1
No connection to General
19500 Visualisation in operation status display
Visualisation did not terminate
19501 orderly
Connection to database The program cannot establish a connection to
19502 interrupted the database.
215 / 215

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Operating instructions

Kirion C Operating Instructions

KIRION C OPERATING INSTRUCTIONS............................................................ 1

2.1 Header line....................................................................................................................................... 8

2.2 Footer line ........................................................................................................................................ 9

2.3 Overview screen ............................................................................................................................ 10

3.2 Cooling ring and IBC blower ....................................................................................................... 17

3.4 Calibration basket ......................................................................................................................... 20

3.5 Bubble breakage monitoring........................................................................................................ 21

3.6 Width measurement...................................................................................................................... 22

3.7 Width regulation ........................................................................................................................... 24

3.8 Take-off .......................................................................................................................................... 25

3.10.6 Winder diagrams.................................................................................................................... 77

3.12 Trend .............................................................................................................................................. 97

3.13 Pellet supply................................................................................................................................. 100

3.14 Heating ......................................................................................................................................... 102

3.15 Profile measurement and control............................................................................................... 105

3.16 Alarm display .............................................................................................................................. 110

3.17 Order ............................................................................................................................................ 113

3.18 Residual quantities management ............................................................................................... 117

3.19 Week and month report.............................................................................................................. 120

3.20 Production protocol .................................................................................................................... 121

3.21 Servicing....................................................................................................................................... 124

3.22 Elapsed time counter................................................................................................................... 125

4 SERVICE AND PARAMETER SETTINGS................................................ 126

4.1 Password entry ............................................................................................................................ 126

4.2 General parameters .................................................................................................................... 127

4.3 Extruder....................................................................................................................................... 128

4.4 Cooling ring and IBC blower ..................................................................................................... 131

4.5 USB............................................................................................................................................... 133

4.6 Calibration basket ....................................................................................................................... 135

4.7 Width measurement.................................................................................................................... 138

4.8 Width regulation ......................................................................................................................... 139

4.9 Take-off ........................................................................................................................................ 140

4.10 Dosing........................................................................................................................................... 142

4.11 Winder.......................................................................................................................................... 143

4.12 Pellet supply................................................................................................................................. 146

4.12.3 Pellet supply blower settings ............................................................................................... 146

4.13 Heating ......................................................................................................................................... 148

4.14 Profile ........................................................................................................................................... 154

4.15 Plant stop ..................................................................................................................................... 160

4.16 Alarms .......................................................................................................................................... 162

4.17 Material database........................................................................................................................ 164

4.18 Supplementary functions and information ............................................................................... 166

4.19 PC Functions ............................................................................................................................... 171

5 ALARM LIST ............................................................................................. 175

2.1 Header line

• Display of the KC serial number.

These fields display

Prints the displayed screen page (screenshot)

Calls up online help. Online help explains the function of the

Calls up Dr. Wise. Dr. Wise helps to answer technical

2.2 Footer line

If a function control has a bright background, it is enabled for activation.

There are more function controls.

Change to the next higher menu level.

Before a value can be changed, this control (enable) must

2.3 Overview screen

This screen is always displayed just after the computer

3.1.1 Extruder drive

The state of readiness, speed [rpm] and

10023 Extruder A, no pellets Monitored by a sensor in the feeder