Technical Report

Nr.: 20 / 09
CBEU

Software update for small- / mid size filling machines

3. Generation - 32 / -35

Version 20.55

CPU STEU: V20.55

CPU TEMP: V20.55
HMI: V20.55
LNG: V20.55
MAX - 4: V18_01_0373.pro

A condition for the software update to Version 20.55 is the conversion of the TR 22 / 07
(Mustpoint)

That means,
• Versionupdate V20.05 (V20.11)
• PLC with type 414-2XG05, 414-2XK05 or 412-2XJ05
• Operating panel / PC from Messrs. Beckhoff

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Nr.: 20 / 09
CBEU

The software update is orderable for the following machines:

Machinentyp
Identifier
CFA … Valid for machine Ordernumber
-32/-35
PLC STEU + 8605.51 045 + 8605.51 048
510
PLC TEMP 8601.98 780
810 8608.51 002 - 8608.51 008
+ 1 Servoaxis US
8693.51 001 - 8693.51 013
312 PLC STEU + 8603.51 054 + 8603.51 062 + 8603.51 065
512 PLC TEMP 8695.51 001 - 8695.51 008 8601.98 781
812 + 5 Servoaxis 8605.51 054 + 8605.51 055
8698.51 001 - 8698.51 002
112 PLC STEU + 8701.51 001 8701.51 132
8601.98 782
712 PLC TEMP 8707.51 001 8707.51 125
112 > 8701.51 133
only PLC STEU 8601.98 783
712 > 8707.51 126
8603.51 016 - 8603.51 076
Except maschine:
310 8603.51 054, 8603.51 062, 8603.51 065
510 PLC STEU + 8605.51 029 - 8605.51 053 8601.98 784
612 PLC TEMP Except maschine:
810 8605.51 045 + 8605.51 048
8606.51 006 - 8606.51 017
8608.51 001
312 > 8693.51 014
only PLC STEU
512 > 8695.51 009 8601.98 785
+ 5 Servoaxis
812 > 8698.51 003

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 Technical Report
Nr.: 20 / 09
CBEU

Software version V20.55 contains:

Mustpoints: none

Thus, the H2O2 evaporators can be operated without internal temperature

sensors, the conversion kit 8601.98 443 must be installed !

Releasepoints:
• Controlling of H2O2-heaters
without internal temperature sensors ..................................(Releasepoint 472)
It is possible to operate the H2O2 evaporators without internal temperature sensors.
Requirement is a build-in conversion kit: Æ 8601.98 443

08 H2O2-Heater
without winding se

• Comments in the PLC program in English ………………….(Releasepoint 259)

The comments in the PLC program are translated to English

• Failure of air conditioning locks the main

drive……………………………………………………………...(Releasepoint 519 / 401)
An error of the air conditioner locks a main drive after a time.

31 Failure of air
conditioning unit b

• Malfunction of wrong production break is eleminated ……..(Releasepoint 476)

Under certain conditions it was possible to turn off the H2O2-System during the
production mode.

26 Stop
production.doc

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CBEU

• Handshake signal with

Herrmann US generators .....................................................(Releasepoint 263)
There will be an evaluation of the welding signal to US generators from Herrmann.

30
Handshake.doc

• Warning flash lamp circular line (Option)….………………….(Releasepoint 200)

An additional flash lamp can be installed in the area of the valve knot, to warn if
the circular line is charged with product or cleaning agent.

34
CIP-Flashlamp.doc

• External counter (Counter Plus)……….………………………(Releasepoint 160)

The external counter is used to count the packages, detect the operating hours and
the measuring of the temperature and humidity.

21 Hour meter
and meter box as

• Profibus connection US generators PC222 ……….…………(Releasepoint 189)

The ultra sonic generators PC222 are connected via profibus.

19 PC222
Branson Profibus.d

• Lubrication error locks maindrive……………………..…..……(Releasepoint 64)

An error of lubrication or an empty grease tank locks the main drive after a time.

32 Lubrication
failure locked the

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• Servo valve control is interrupted when

compressed air is off…………………………………………..(Releasepoint 459)
When the compressed air supply is switched off, the powersupply of the control
valves is shut off to avoid a strong heating of the control valves.

35 Servo valves
control is interrupt

• Reset signal ultrasonic generators …………………………..(Releasepoint 282)

All ultrasonic errors can now be confirmed with the acknowledgment key at the
HMI / RHMI.

• Selection acid and caustic with spray pistol…………….......(Releasepoint 206)

When acid or caustic were selected for the spray pistol a direct change to the
respective other medium is not possible. You have to select water first.

29 Dial acid leach

with spear.doc

• ELAU: Selection new law of motion for ejector…………….(Releasepoint 441)

For optimal discharging of 500 ml packs a new law of motion for the ejector has been
created.

20 Ejector curve
format change.doc

• ELAU: Safe operating of hand wheel ……………………….(Releasepoint 479)

Secure synchronization of the chain on the mandrel wheel when the hand wheel is
activated.

42 Start-hand
wheel.doc

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CBEU

• ELAU: Umstellung V12 auf V16……………………………..(Releasepoint 323)

The EPAS version V12.20 was replaced by the V16.24 version. Only mid size
machines with US servo axis are affected.

14 Update of the
project SIG_CBTE_

• Elimination of errormessage:
"Servos: r.p.e. servos not synchronous to r.p.e. main……..(Releasepoint 458)
This error was installed for testing and is eliminated now.

• Sporadic failure of a circuit breaker …………………………(Releasepoint 619)

The load of a 24V circuit was at the upper limit of the used 6A breaker. This breaker
was replaced by a 10A type.

TB 2708
Multiple-Disc Clutc

• Diagnostic counter in HMI……………………………………..(Releasepoint 607)

Two new pages are available at the HMI. They are made to track the operation-hours
and power cycles from 64 components. The first 32 components are predefined.

09
Diagnosecounter.d

• Monitoring of compressed air at the dedusting for each track

(Option only for small size filling machines ………….………(Releasepoint 170)
The compressed air for dedusting is monitored for each track.

• Single Diversion at standard Siemens machines …………..(Releasepoint 620 CBCN)

Defective packs can now be ejected individually by their own turnout.
Condition is conversion kit (see Table: Conversion kit numbers single diversion)

08 H2O2-Heater
without winding se

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CBEU

Conversion Kit Numbers Single Diversion

Machinentyp
CFA … Identifier Valid for machine Ordernumber
-32/-35
PLC STEU + 860551045 + 860551048 Direction
510
PLC TEMP drive-side
810 860851002 - 860851008
+ 1 Servaxis US 8605.35 050
869351001 - 869351013

312 PLC STEU + 860351054 + 860351062 + 860351065 Direction

512 PLC TEMP 869551001 - 869551008 drive-side
812 + 5 Servoaxis 860551054 + 860551055 8605.35 050

869851001 - 869851002
112 PLC STEU + 870151001 870151132
Not available
712 PLC TEMP 870751001 870751125
Direction
> 870151133
drive-side
112 8701.35.404
Only PLC STEU
712 Direction
> 870751126
operator's-side
8701.35 405
860351016 - 860351076
Except maschine:
310 860351054, 860351062, 860351065
860551029 - 860551053 Direction
510 PLC STEU +
drive-side
612 PLC TEMP Except maschine
8605.35 050
810 860551045 + 860551048
860651006 - 860651017
860851001
> 869351014 Direction
drive-side
312 > 869551009
only PLC STEU 8601.35.401
512
+ 5 Servoaxis Direction
812
> 869851003 operator's-side
8601.35 402

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CBEU

General points:
• New HMI service switches on HMI "checklist constant"
On HMI page “Constant” new service switches for ultrasonic and signal exchange
CIP / UHT were placed.

25 Service Switch
2 UHT and handsh

• CombiSwift / -Fit
The selection of fitments was standardized in small and mid sized machines.

28 CF.doc

• New HMI service switch: Close Fit station

This switch allowes for service reasons to put the Fit forming station in operating
position.

24 Service switch
Fit.doc

• Powerless switching of the contactors

The contactors are only switched ON / OFF when the controller is savely turned off.
This powerless switching protects the contacts of the contactors.

• Error "emergency shutdown" H2O2 heating with detailed specification of the reason
After an emergency shutdown of the H2O2 heaters the reason is displayed on the
HMI.

40 Emergency
shutdown caused

• Combitop heaters are not turned on during activation pattern

To avoid burning the sleeves which are under the Combitop heaters during activation
pattern the combitop heaters are turned off during activation pattern.

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• Logging of the current counter values when reset button-pressing

When pressing the reset button on HMI for the counter values first all counter values
are recorded again exactly. Then all counter values are set to zero.

• Release US pressure limit

The HMI input limits for the US welding pressure was increased from 3000mbar to
6000mbar.

• Size of the *. prl files has been reduced

Due to the continuously recording of some parameters with a small delta value the
log files on the HMI PC were quite large.

• ELAU: Setup mode with confirmed checklist

The setup axis mode is confirmed via checklist. The operator is warned that the servo
motors can collide during setup mode.

17 Adjust mode
with checklist to co

• Zyklon-hoover
Some customers have an external suction system for dedusting. It is secured by a
motor protection switch. In case of a failure of the motor protection switch an error
message appears on the HMI.

• Bus error shuts off heating contactors

A DP-bus fault of the operating panel switches off the heating contactors.

• Default: pusher calculation

If there is a separate pulser valve for each track the calculated pusher is the default.

• Error "Jam off-conveyor" self resetting

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CBEU

• Start backup tool with HMI service switch

The program BackUpHMIPC runs an online backup of the complete HMI-PC during
normal operation. The image is stored on an USB memory stick (DataSafe).
Requirement is a build-in conversion kit: Æ 8730.90.004

23 Brief
description of the

• Temperature reduction after a main drive stop from 0s to 45s increased.

• Cell shower (Option, only for small format machines)

An additional cell chain shower is available.
Specially fitted sprayballs are used.
Requirement is a build-in conversion kit: Æ 8707.41.013

Bugfixing:
• Input values pusher cycle calculation
If both HMI-input values for the calculated pusher are zero the PLC stopped.

• Wrong HMI display stock magazine

The stocks in magazine for small format machines were not displayed correctly due
to a wrong conversion factor in the HMI.

• Stepping through H2O2 steamsterilisation

It was possible to reach the normal sterile production mode with stepping through
steamsterilisation. Now only the “Test sterile production” mode is possible.

• Service switch "Heaters OFF" is turned on, during sterilisation

Using the service switch “Heaters OFF” during sterilization allowed to reach the
normal sterile production mode. Now only the “Test sterile production” mode is
possible.

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Nr.: 20 / 09
CBEU

Changes from the previous software update version V20.05 (V20.11)

• Sterile productchange / sterile productchange with sterile water rinsing

02 Sterile Water
Flush.doc

• Advanced filling management

03 Extended Fill
Management.doc

• Startup procedure and output adjustment downstream

04 Startup
Procedure & Outp

Delivery:
DVD with data for the PLC, HMI and LNG-language files and printed electrical circuit
diagram and description of the software changes.

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