Operating Manual

Zelos
Can Cutting and Brushing Machine

SI-DOC-35618V1.0
© 2019 PackSys Global, Thailand
Replication, distribution and / or editing of this document and the use and distribution of its content is prohibited
unless explicitly permitted. Violation obligates compensation for damages. All rights reserved in case of the issue
of a patent, utility patent or design patent.
Table of contents

Table of contents

1 About this documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Operating and service personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.3 Conventions used in this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.4 Disclaimer of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.5 Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.6 Support / Contact address. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.7 Revisions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 General safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.3 Safety symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.4 Machine-specific safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.4.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.4.2 Safety doors and covers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.4.3 Main power switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.4.4 Emergency stop switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.4.5 Machine-specific safety symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2.5 User levels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.6 Residual risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.6.1 Residual risks during operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.6.2 Residual risks during setup and maintenance . . . . . . . . . . . . . . . . . . 2-10

3 Description of the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.1 Process overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 Machine overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.2.1 Main drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.2.2 Outfeed chain drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.2.3 Press transfer conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.2.4 Intermediate drum and loading drum . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.2.5 Feeding pusher unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.2.6 Turret and working stations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.2.7 Wall length cutting station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.2.8 De-burring station. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3.2.9 Brush segment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3.2.10 Mandrel drive and brake systems . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3.2.11 Brushing stations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.2.12 Take-off unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3.2.13 Stripper unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
3.2.14 Scrap extraction unit (Cyclone unit) . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3.2.15 Dust collection ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

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3.3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

3.3.1 Utilities data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
3.3.2 Machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
3.3.3 Product data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
3.3.4 Chain data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
3.3.5 Environmental conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
3.3.6 Noise level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
3.3.7 Location of the name plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
3.3.8 Machine layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

4 Transport and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.1 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1.1 Unpacking and inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1.2 Lifting the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1.3 Transporting the packed machine . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.1.4 Storing the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.2.1 Rust protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.2.2 Cooling system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

5 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1 User interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1.1 Operating panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1.2 Signal tower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.2 Screen structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.2.1 Title bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5.3 Navigation keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.4 Appearance of touch keys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.5 Common touch keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.6 Setting the parameter values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5.7 User levels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5.8 Line overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5.9 Machine graphic – Zelos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
5.10 Sub-navigation bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
5.11 Welcome Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
5.12 Production screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
5.12.1 PRODUCTION: Home screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
5.12.2 PRODUCTION: Turret and outfeed screen . . . . . . . . . . . . . . . . . . . 5-17
5.12.3 PRODUCTION: Brushing 1 screen . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
5.12.4 PRODUCTION: Brushing 2 screen . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
5.12.5 PRODUCTION: Cutting screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36
5.13 Recipe screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
5.13.1 RECIPE: Home screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
5.13.2 Common elements of the RECIPE screens . . . . . . . . . . . . . . . . . . . 5-44
5.13.3 RECIPE: Turret and Outfeed screen . . . . . . . . . . . . . . . . . . . . . . . . 5-46
5.13.4 RECIPE: Brushing screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
5.13.5 RECIPE: Cutting screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48
5.14 Alarm screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
5.14.1 ALARM: Current Alarm screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
5.14.2 ALARM: Historical Alarm screen . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50
5.15 Settings screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51
5.15.1 SETTINGS: Home screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51

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5.16 Information screens. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53

5.16.1 INFORMATION: Production Counter screen . . . . . . . . . . . . . . . . . . 5-53
5.16.2 INFORMATION: Power monitoring screen . . . . . . . . . . . . . . . . . . . 5-55
5.17 Operating modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-58
5.17.1 Machine startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-58
5.17.2 Setup mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59
5.17.3 Inching mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59
5.17.4 Auto mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-60
5.17.5 Interrupting the machine operation. . . . . . . . . . . . . . . . . . . . . . . . . . 5-61
5.17.6 Restarting the machine after an interruption . . . . . . . . . . . . . . . . . . 5-61
5.17.7 Stopping the machine in case of an emergency . . . . . . . . . . . . . . . 5-61
5.17.8 Restarting the machine after an emergency stop. . . . . . . . . . . . . . . 5-61
5.17.9 Shutting down the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-62
5.18 Managing recipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-63
5.18.1 Creating a new recipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-63
5.18.2 Loading a recipe to the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-64
5.18.3 Editing a recipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-64
5.18.4 Deleting a recipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67
5.19 Operating the Can cutting and brushing line . . . . . . . . . . . . . . . . . . . . 5-68
5.19.1 Setting the Zelos machine up for production . . . . . . . . . . . . . . . . . . 5-68
5.19.2 Prerequisites for starting the line . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68
5.19.3 Starting the Washing machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68
5.19.4 Starting the line in ‘Auto’ mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-69
5.19.5 Interrupting production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-69
5.19.6 Resuming production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-69
5.19.7 Shutting down the Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-70
5.19.8 Shutting down the Zelos machine . . . . . . . . . . . . . . . . . . . . . . . . . . 5-70
5.19.9 Operating the Zelos machine in Inching mode. . . . . . . . . . . . . . . . . 5-70
5.19.10 Operating the Zelos machine in Setup mode . . . . . . . . . . . . . . . . . 5-71

6 Size part changeover and settings . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.1 About size parts changeover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.1.1 Tools required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.1.2 Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 Necessity for size part change and settings . . . . . . . . . . . . . . . . . . . . . 6-2
6.3 Changing the mandrels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.4 Protecting the mandrels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.5 Feeding drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6.5.1 Changing the feeding drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6.5.2 Aligning the feeding drum pocket against the mandrel . . . . . . . . . . . 6-9
6.5.3 Adjusting the gap between the feeding drum and the mandrel . . . . . 6-10
6.6 Intermediate drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
6.6.1 Changing the intermediate drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
6.6.2 Changing the roll sheet below the intermediate drum . . . . . . . . . . . . 6-12
6.6.3 Adjusting the intermediate drum against the feeding drum . . . . . . . . 6-13
6.6.4 Adjusting the intermediate drum against the roll sheet . . . . . . . . . . . 6-14
6.6.5 Re-engaging the overload clutch after a jam . . . . . . . . . . . . . . . . . . . 6-15
6.7 Feeding pusher unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
6.7.1 Setting the first feeding pusher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
6.7.2 Resetting the feeding pusher unit after a crash . . . . . . . . . . . . . . . . . 6-17

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6.8 Wall length cutting station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19

6.8.1 Replacing the knife revolver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
6.8.2 Replacing the knife holder in the revolver . . . . . . . . . . . . . . . . . . . . . 6-20
6.8.3 Replacing the knife in the knife holder . . . . . . . . . . . . . . . . . . . . . . . . 6-21
6.8.4 Setting the knife revolver in the setting jig . . . . . . . . . . . . . . . . . . . . . 6-22
6.8.5 Adjusting the cutting knife-to-mandrel pressure . . . . . . . . . . . . . . . . . 6-26
6.8.6 Adjusting the wall cutting length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
6.9 De-burring station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
6.9.1 Adjusting the de-burring roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
6.10 Brushing station. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
6.10.1 Replacing the brush roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
6.10.2 Adjusting the brush roller against the mandrel . . . . . . . . . . . . . . . . . 6-32
6.10.3 Angular adjustment of the brush roller . . . . . . . . . . . . . . . . . . . . . . . 6-33
6.10.4 Adjusting the oscillation stroke of the brush roller . . . . . . . . . . . . . . 6-34
6.10.5 Moving the brushing station to the service position . . . . . . . . . . . . . 6-35
6.10.6 Removing the covers of the brushing station . . . . . . . . . . . . . . . . . . 6-36
6.10.7 Replacing the grindstone of the brush cleaning unit . . . . . . . . . . . . 6-39
6.11 Pressure rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
6.11.1 Changing the pressure rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
6.12 Take-off unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42
6.12.1 Changing the product grippers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42
6.12.2 Aligning the chain pegs to the product grippers . . . . . . . . . . . . . . . . 6-43
6.13 Chain peg guiding devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44
6.13.1 Adjusting the chain peg guiding wheel . . . . . . . . . . . . . . . . . . . . . . . 6-44
6.13.2 Adjusting the chain peg guiding plate. . . . . . . . . . . . . . . . . . . . . . . . 6-45
6.14 Stripper unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46
6.14.1 Changing the stripper plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46
6.14.2 Adjusting the end ring retaining brush . . . . . . . . . . . . . . . . . . . . . . . 6-47
6.15 Scrap suction channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48
6.16 Press transfer conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50
6.16.1 Adjusting the guide plate (at the infeed). . . . . . . . . . . . . . . . . . . . . . 6-50
6.16.2 Adjusting the guide plate (at the outfeed). . . . . . . . . . . . . . . . . . . . . 6-51
6.16.3 Changing the roll sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-53

7 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.1 General information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.1.1 Safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.1.2 Maintenance schedule symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.1.3 Maintenance activity symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.1.4 Tools required for maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.1.5 Lubricants used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.1.6 Cleaning solvents used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.2 Maintenance and lubrication schedules . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.2.1 Daily maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.2.2 Weekly maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7.2.3 Monthly maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7.2.4 Quarterly maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
7.2.5 Half yearly maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
7.2.6 Yearly maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17

4
Table of contents

7.3 Maintenance activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19

7.3.1 Replacing the mandrel drive belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
7.3.2 Replacing the mandrel brake belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
7.3.3 Repairing the damaged edge of the knife . . . . . . . . . . . . . . . . . . . . . 7-21

8 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.1 About troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.1.1 Description of error levels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.2 Error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

9 Disposal of the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

5
Table of contents

6
1 - About this documentation
Introduction

1 About this documentation

1.1 Introduction
This operating manual is intended for the users of Can Cutting and Brushing
Machine, Zelos. The manual contains information about the correct
procedures for setup, operation and maintenance of the Zelos machine.

The instructions given in this manual must be fully obeyed. The manual must
be kept where you can find it easily. The manual is a part of the machine.

1.2 Operating and service personnel

The operating and service personnel must fully understand and obey all the
safety, operating and maintenance instructions contained in the manual. They
must also know how to find the necessary information in the manual. They will
be trained and instructed in person by PackSys Global before the machine
is put to its intended use.

1.3 Conventions used in this manual

These conventions are used in this manual:

Numbering Convention / Example

Page 1-4 means Page 4 of Chapter 1
Chapter Chapter 1, 1.1 or 1.1.1 (Up to three heading
levels)
Figure Fig. 3-12 means Figure 12 of Chapter 3
Call-outs in figures The call-outs are identified in the legend or the
text related to the figure.

1.4 Disclaimer of liability

Every effort has been made to keep the information contained within this
manual updated and accurate as of the date of publication. Nevertheless,
discrepancies can not be ruled out. Any liability and warranty for the accuracy
of this information is excluded. The information in this manual are reviewed
at periodical intervals. PackSys Global reserves the right to make changes
at any time.

1.5 Copyright
Replication, distribution and / or editing of this document and the use and
distribution of its content is prohibited unless explicitly permitted. Violation
obligates compensation for damages. All rights reserved in case of the issue
of a patent, utility patent or design patent.

Operating Manual V1.0 Zelos 1-1

1 - About this documentation
Support / Contact address

1.6 Support / Contact address

PackSys Global (Thailand) Ltd.
119 Moo 5 Soi 12, Highway No. 36
Tumbol Makhamkoo, Amphur Nikhom Phattana
Rayong Province 21180, Thailand.
Phone: +66 38 917 164
Fax: +66 38 893 139
Hot line: + 41 34 4273318
E-mail: service@packsysglobal.com
Internet: www.packsysglobal.com

1.7 Revisions
Revision Date Changes
V1 Nov 2019 First release

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2 - Safety
Intended use

2 Safety

2.1 Intended use

This manual is about the Zelos machine, designed for cutting the impact-
extruded aluminium cans to the required length and brushing the can surface.

Any other use is not considered to be consistent with the intended use, and
the manufacturer/supplier is not liable for any damage resulting therefrom.
However, its intended use still involves risks of injury to users and risks of
damage to the machine or other property if used incorrectly.

2.2 General safety information

This chapter provides information about the machine safety and the usage of
general and machine-specific safety symbols. All safety instructions must be
understood and strictly followed. PackSys Global disclaims all responsibility
for any accident caused by personnel who do not obey the instructions for use.
PackSys Global is not liable for any accidents caused by changes or removal
of any of the installed safety devices.

2.3 Safety symbols

The following general safety symbols and warning messages with signal words
appear throughout the manual. The signal words indicate different severity
levels. Furthermore, every safety message consists of a hazard description,
its consequences if not avoided and how the hazard can be avoided.Safety
stickers must not be removed from the machine. If the stickers are worn out
or damaged, replace them immediately.

DANGER
Indicates a hazardous situation which, if not avoided, will result in
death or serious injury.

WARNING
Indicates a hazardous situation which, if not avoided, could result in
death or serious injury.

CAUTION
Indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury.

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2 - Safety
Machine-specific safety

2.4 Machine-specific safety

2.4.1 Overview
The locations of the various machine-specific safety equipment on the Zelos
machine are illustrated below:

1 3 4
Fig. 2-1 Machine-specific safety equipment - 1

1. Emergency stop switch

2. Front safety door with safety interlock
3. Side safety door with safety interlock
4. Safety door with safety switch

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2 - Safety
Machine-specific safety

5 5
Fig. 2-2 Machine-specific safety equipment - 2

5. Safety doors with safety switches

6. Side safety door with safety interlock
7. Signal tower

10
9
8

Fig. 2-3 Machine-specific safety equipment - 3

8. Safety cover with safety switch

9. Access door with safety switch
10. Access door with safety switch

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2 - Safety
Machine-specific safety

14
13
ON

12

OFF
11

Fig. 2-4 Machine-specific safety equipment - 4

11. Safety doors of the electrical cabinet with lock

12. Main power switch
13. Emergency stop switch
14. Power monitoring unit

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2 - Safety
Machine-specific safety

2.4.2 Safety doors and covers

The different doors and covers with their functions are explained in the
following table:

Type of doors and Function

covers
Safety doors with safety These safety doors remain locked when the
interlocks (2), (3) and (6) machine is running and can only be opened when
the machine is stopped.
Safety doors with safety These safety doors with magnetic/mechanical
switches (4) and (5) locks cover the moving elements like cranks,
transport chains, belt and chain drives and
electrical elements.
If these doors are opened during operation, the
machine stops immediately. If the machine is
synchronised with the upstream machine, the
upstream machine also stops immediately.
Safety doors (11) of the These doors cover the elements inside the
electrical cabinet electrical cabinet. Keep these doors closed
during operation.
Safety cover and access These doors cover the press transfer conveyor.
doors with safety If these doors are opened during operation, the
switches (8), (9) and machine stops immediately. If the machine is
(10). synchronised with the upstream machine, the
upstream machine also stops immediately.
Fixed guarding and The machine also has fixed guarding and covers
covers to cover other moving elements of the machine.

WARNING
Removal of fixed guarding or doors with mechanical lock does not
prevent the operation of the machine.
Risk of injury to fingers or hands when the machine is operated
without its fixed guarding.
– Do not operate the machine without the fixed guards and covers
of the machine.
– Install all the fixed guards and covers again on the machine after
a servicing of the machine is done.

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2 - Safety
Machine-specific safety

2.4.3 Main power switch

The functions of the Main power switch are as follows.

P
I ON
RI
+T

OOFF
C

Ø 4...8
RE
SE
T

Fig. 2-5 Main power switch

ON Switches ON the machine.

The machine must be switched ON only when the machine and connected
equipment are ready for operation.

OFF Switches OFF the machine.

After the machine is switched OFF, the Main power switch can be locked to
prevent an unexpected startup of the machine. To lock the Main power switch,
press the button on the Main power switch and lock it.

Trip The trip function is a safety feature to protect the machine during a power failure
or a power surge. The Main power switch automatically turns to the trip position
and the machine stops.

The trip function is an automatic function. The Main power switch

cannot be manually turned to the trip position.

Reset If the Main power switch has tripped, manually turn the Main power switch to
the Reset position after the power supply has resumed or the power surge has
passed. Turn the Main power switch to ON position to switch ON the machine.

2.4.4 Emergency stop switch

When you push the emergency stop switch, the machine and its connected
equipment stops immediately. The machine and its connected equipment
cannot be started again unless you reset the switch by turning it in the direction
marked on the switch. Use this switch only in case of an emergency.

Fig. 2-6 Emergency stop switch

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2 - Safety
Machine-specific safety

Emergency stop switches on the Can cutting and Internal coating lines

The whole line is divided into different groups of machines for the control of
emergency stop function. When you push an emergency stop switch, only that
group of machines on which the emergency stop switch was located will stop
immediately. The operation of other groups of machines will not be affected.

The can cutting line includes Zelos, Washing machine (PW-6-200) and Accu-
PW. The internal coating line includes the JLD, IBO, and Accu-IBO.The
emergency stop switches are installed at the following locations.

3 2 1

12 8 7

11 10 9 6 5 4

Accu-IBO IBO JLD Accu-PW PW-6-200 Zelos

Fig. 2-7 Emergency stop switches – Can cutting and internal coating lines

1. Zelos main electrical cabinet

2. Washing machine (PW-6-200) main electrical cabinet
3. JLD + IBO main electrical cabinet
4. Zelos operating panel
5. Washing machine (PW-6-200) operating panel
6. Accu-PW operating panel
7. Accu-PW electrical cabinet (Rear)
8. JLD operating panel (Rear)
9. JLD electrical cabinet
10. IBO electrical cabinet (Rear)
11. Accu-IBO operating panel
12. Accu-IBO electrical cabinet (Rear)

▪ Operating any of the emergency stop switches (1) will stop the Press
machine, Zelos, washing machine (PW-6-200), Accu-PW, JLD, IBO and
Accu-IBO immediately.
▪ Operating the emergency stop switch (4) will stop the Zelos immediately.

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2 - Safety
Machine-specific safety

▪ Operating any of the emergency stop switches (2), (5), (6), and (7) will stop
the Press machine, Zelos, washing machine (PW-6-200), and Accu-PW
immediately.
▪ Operating any of the emergency stop switches (3), (8), (9), (10), (11),and
(12) will stop the JLD, IBO, and Accu-IBO immediately.

2.4.5 Machine-specific safety symbols

The machine-specific safety symbols indicate machine-specific hazards.

DANGER
High voltage hazard.
Any contact with live parts leads to an immediate threat to life due to
electric shock. Damage to the insulation or individual components can
be lethal.
– Only a qualified and authorized electrician is allowed to work on
electrical equipment.
– Turn off the mains power switch and secure it with a padlock to
prevent any unintended restart of the machine.
– If there is damage to electrical insulation, immediately turn off the
mains power switch and repair the insulation.
– Before you start working on the electrical parts, make sure that the
parts are free of electrical power. Strictly comply with all the
mandatory safety procedures related to each of these steps:
- Unlocking
- Secure against switching on
- No voltage
- Short circuit and earthing
- Cover or safeguard any other connected electrical parts.
– Do not bridge any fuses.
– Keep moisture away from live electrical parts. This may lead to
short circuits.

WARNING
Moving machine components.
Risk of cutting, crushing or shearing of fingers or hand.
– Keep clear of moving or rotating parts of the machine.
– If these parts must be serviced, turn off and lock out the main power
switch to prevent any unexpected startup of the machine.

WARNING
Rotating machine components.
Risk of drawing in and/or crushing of fingers or hand.
– Keep clear of moving or rotating parts of the machine.
– If these parts must be serviced, turn off and lock out the main power
switch to prevent any unexpected startup of the machine.

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2 - Safety
User levels

2.5 User levels

The different user levels for operating, setting and maintaining the machine
are described as below:

Operator level After the machine is switched ON, the user need to enter the password for the
(Level 1) respective user level. The operator level is a password-protected level that
allows the user to start and work on the machine. In this level, it is not possible
to change any parameters or settings.

Supervisor/Setter level This password-protected level allows the user to change certain machine
(Level 2) parameters, load a recipe and configure the machine functions. Access to this
level is given only to supervisor/setter trained by PackSys Global.

Technician level This password-protected level allows the user to change even more machine
(Level 3) settings and configurations as compared to Level 2 access. Access to this level
is given only to supervisors and technicians trained and certified by PackSys
Global.

2.6 Residual risks

This machine has been designed and constructed to fully meet all the
applicable CE standards and directives on machinery. An iterative risk
assessment and risk reduction procedure has been done to eliminate or
minimize the hazards that can occur when the machine is used. But some
hazards still remain. These residual risks, their consequences and steps to
prevent such consequences must be fully understood from this manual and
at the machine before the machine is put to use.

2.6.1 Residual risks during operation

During normal operation for production, all the machine doors and covers are
closed and there is not much risk to the user. But during maintenance and
setups, when the doors and covers must be opened, there are some risks to
the user. All work after opening the safety doors or covers must be done very
carefully.

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2 - Safety
Residual risks

2.6.2 Residual risks during setup and maintenance

During maintenance, setups or size part changes, the machine must be
operated at inching speed with the doors and protective covers open. But the
machine can be operated only when the dead man’s switch at the operating
panel of the controlling machine is used. This is to make sure that both hands
of the user are engaged and away from the machines when they are operated.

If more than one person must work with the machine, the residual risks at the
machine components as given below must be fully understood.

WARNING
Removal of fixed guarding or doors with mechanical lockdoes not
prevent the operation of the machine.
Risk of injury to fingers or hands when the machine is operated
without its fixed guarding.
– Do not operate the machine without the fixed guards and covers
of the machine.
– Install all the fixed guards and covers again on the machine after
a servicing of the machine is done.

WARNING
Rotating machine components.
Risk of drawing in and/or crushing of fingers or hand.
– Keep clear of moving or rotating parts of the machine.
– If these parts must be serviced, turn off and lock out the main power
switch to prevent any unexpected startup of the machine.

WARNING
Moving machine components.
Risk of cutting, crushing or shearing of fingers or hand.
– Keep clear of moving or rotating parts of the machine.
– If these parts must be serviced, turn off and lock out the main power
switch to prevent any unexpected startup of the machine.
If the safety doors at the rear or sides must be opened or the safety covers
removed for any maintenance, service or cleaning jobs, these rules must be
obeyed:

▪ Stop the machine before opening safety doors or removing covers.

▪ If it is necessary to monitor the moving machine components, stay clear
at a safe distance.
▪ Before starting the machine after maintenance work, make sure that all
screws and bolts are correctly tightened and all safety doors and covers
are closed and correctly locked.

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2 - Safety
Residual risks

Press transfer conveyor

The press transfer conveyor transfers the cans from the extrusion press to the
intermediate drum of the Zelos machine. There are risks of squeezing hands
or fingers between the transfer drum and the intermediate drum. Be careful
while you are near this area.

Feeding drum and pushers

There are risks of squeezing or crushing of fingers or hand at the intermediate
drum - feeding drum interface. There is also a high nip risk between the first
feeding pusher and the feeding drum during the inward stroke of the feeding
pusher.

Turret and mandrels

The motion of the turret is dangerous because of its sudden stop-and-go
function. Risks of crushing and entanglement are high when the mandrels are
near the working stations.

Wall cutting station

The danger area of the wall cutting station is the area where the sharp cutting
tool will touch the can.There is a high risk of fingers being caught between the
cutting tool and the can, when the machine is operated at inching speed.

Strip removal station

There is a high risk of fingers getting caught at the stripping unit because of
the stroke motion and the sharp edge at the stripper plates, Be very careful
while you get access to this area while the machine is operated at inching
speed.

Take-off unit
During the outward stroke function, there are risks of knocking and impact to
the head of the user. During the inward stroke of the take-off unit, there is a
risk of crushing and squeezing hands or fingers between the grippers and
mandrels or chain pegs.

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2 - Safety
Residual risks

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2-12 Zelos Operating Manual V1.0

3 - Description of the machine
Process overview

3 Description of the machine

This chapter consists of three sections:

▪ Process overview
▪ Machine overview
▪ Technical data

The process overview and the machine overview sections briefly describe the
purpose and function of the various machine modules and the workflow of
products through the machine.

The technical data section lists the machine data, product data, and layouts
of the machine.

3.1 Process overview

The Zelos machine is designed to trim products to the required length and to
brush and clean the outer surface of products to help coating and printing on
the product surface. The workflow of products in the machine is as follows:

11 2
1

10
3

9 4
5

8 6
7

Fig. 3-1 Zelos - Process overview

1. Press transfer conveyor

2. Intermediate drum
3. Loading drum
4. Feeding pusher unit
5. Turret
6. Wall length cutting station
7. De-burring station
8. Wall brushing stations
9. Take-off unit

Operating Manual V1.0 Zelos 3-1

3 - Description of the machine
Process overview

10. Stripper unit

11. Scrap suction unit (cyclone unit)

▪ The press transfer conveyor (1) transfers the raw aluminium products from
the impact-extrusion press to the intermediate drum (2).
▪ The loading drum (3) positions the products at the loading station for
loading on to the mandrel.
▪ During the dwell time of the turret (5), the feeding pusher unit (4) pushes
a product held on the feeding drum onto the mandrel.
▪ At the wall length cutting station (6), the products are cut to the required
length.
▪ At the de-burring station (7), the burrs (after cutting) are removed.
▪ The products then pass through the wall brushing stations (8) where they
are brushed.
▪ The take-off unit (9) then pulls three products out of the mandrels and puts
them on the pegs of the outfeed chain.
▪ The stripper unit (10) removes the scrap end-rings that are cut off from
the product at the wall length cutting station. In case a product is not
removed from the mandrel during take-off, the product is removed by the
stripper unit.
▪ The scrap suction unit (cyclone unit) (11) transfers the scrap end-rings to
a collection bin at the rear side of the machine.

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3 - Description of the machine
Machine overview
Main drive

3.2 Machine overview

The main components of the Zelos machine are:

3.2.1 Main drive

A single servomotor (1) drives the mandrel turret, feeding pusher, and the take-
off unit through a spur gear unit (2), cams, linkages, timing belts, and pulleys
collectively called the main drive. Separate drives are provided for the wall
length cutting station, wall brushing station, loading drum, and the mandrels.
The turret and the units connected to the main drive can be manually inched
by using the handwheel (3).

2
3
1

Fig. 3-2 Main drive

1. Servomotor
2. Spur gear unit
3. Handwheel

3.2.2 Outfeed chain drive

A servomotor located on the machine frame drives the outfeed chain of the
Zelos.

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3 - Description of the machine
Machine overview
Press transfer conveyor

3.2.3 Press transfer conveyor

The press transfer conveyor (1) transfers the products from the extrusion press
to the intermediate drum at the end of the conveyor. The conveyor is driven
by a separate servomotor through timing belts and pulleys. The safety cover
(2) can be opened for inspection and maintenance of the conveyor. The two
access doors (3) and (4) can be used to remove cans if the cans fall off the
conveyor. If the covers (2), (3), and (4) are opened while the machine is in
operation, the machine stops immediately. The cover (5) at the bottom of the
press transfer conveyor can also be opened for inspection and maintenance.
The product presence sensor (6) checks for the presence of products on the
press transfer conveyor. The product length check sensor (7) checks for very
long products on the press transfer conveyor. If a product is short or very long,
it is blown off at the product rejection chute (8) of the press transfer conveyor.
A sample product ejection chute (9) is installed on the press transfer conveyor
for collecting samples for testing and inspection.

3
2

7 6

8 9 5
Fig. 3-3 Press transfer conveyor

1. Press transfer conveyor

2. Safety cover 1
3. Access door 1
4. Access door 2
5. Bottom cover
6. Product presence sensor
7. Product length check sensor
8. Product rejection chute
9. Sample product ejection chute

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3 - Description of the machine
Machine overview
Intermediate drum and loading drum

3.2.4 Intermediate drum and loading drum

The products at the end of the press transfer conveyor are picked up by the
transfer drum (1) and dropped into the pockets of the intermediate drum (2).
The roll sheet (3) guides the products during the transfer of products from the
transfer drum to the intermediate drum. The products are then released into
the pockets of the loading drum (4). The roll sheet (5) guides the products
during the transfer of products from the intermediate drum to the loading drum.
The products are held by vacuum on the transfer drum, intermediate drum,
and loading drum pockets.The intermediate drum is driven by the press
conveyor drive through timing belts and pulleys. The loading drum is driven
by a separate servomotor.

3
1

Fig. 3-4 Intermediate drum and loading drum

1. Transfer drum
2. Intermediate drum
3. Roll sheet
4. Loading drum
5. Roll sheet

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3 - Description of the machine
Machine overview
Feeding pusher unit

3.2.5 Feeding pusher unit

The feeding pusher unit consists of two pushers. The first feeding pusher (1)
partially loads a product onto the mandrel. The second feeding pusher (2)
pushes the product completely onto the mandrel.
For safety, both feeding pushers are equipped with overload protection
devices. In case of excessive resistance during product loading, the pushers
retract from their working positions and the machine goes to a fast stop.

Fig. 3-5 Feeding pusher unit

1. First feeding pusher

2. Second feeding pusher

3.2.6 Turret and working stations

The function of the 16-mandrel turret is to position the mandrels with the
products at various stations for different operations. The turret indexes in the
clockwise direction.

15

14 16
13 1

12 2

11 3

10 4

9 5
8 6

Fig. 3-6 Turret schematic

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3 - Description of the machine
Machine overview
Turret and working stations

Station 1 Product loading station 1: During the dwell time of the indexer, the loading
drum positions the product accurately in front of the mandrel. Simultaneously,
the first feeding pusher loads the product by approximately half its length onto
the mandrel, assisted by suction through the mandrel.

Station 2 Product loading station 2: The second feeding pusher completes the product
loading by fully loading it onto the mandrel. The products are held on the
mandrels by vacuum.

Station 3 Empty station: This is an empty station. The product presence sensor checks
the presence and correct position of products. The mandrel belt drive system
starts to rotate the mandrels from station 3. The drive continues spinning the
mandrels until station 8.

Station 4 Wall length cutting station: This station consists of the wall length cutting
unit. The product is cut to the required length and the scrap end-ring is
separated from the product.

Station 5 De-burring station: The de-burring unit at this station rolls out the burrs
formed on the product during the wall length cutting process.

Station 6 Brushing station 1: The products are brushed by the brushing wheel at this
station.

Station 7 Empty station: This is an empty station.

Station 8 Brushing station 2: The products are brushed again by the brushing wheel
at this station.

Stations 9, 10, and 11 Empty stations: A braking belt contacts the mandrel drive pulleys starting at
station 9 through station 2 and keeps the mandrels stationary during the take-
off cycle and during the removal of scrap end-rings.

Stations 12, 13, Unloading stations: At the unloading stations 12, 13, and 14, a compressed
and 14 airjet ejects the products out of the mandrels to the approaching take-off
grippers. In case a product is not successfully removed at stations 12, 13, or
14, the product will be removed from the mandrel at station 15 by the stripper
unit.

Stations 14 and 15 End-ring removal station: A stripper unit removes the scrap end-rings which
are cut off from the products, before new products are loaded on the mandrels.
The scrap end-rings are collected by a separate scrap extraction unit (Cyclone
unit).

Station 16 Empty station: This is an empty station. The mandrels are changed at this
station during a size part changeover.

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3 - Description of the machine
Machine overview
Wall length cutting station

3.2.7 Wall length cutting station

At station 4 of the turret, the product is trimmed to the required wall length.
The product is cut by a revolver-type cutting unit (1). The revolver-type cutting
unit consists of a knife revolver (2) with four knives (3). A spacer roll (4) on
the knife holder prevents the knife from cutting into the mandrel. After a set
number of products are cut, the knife revolver automatically indexes to the next
knife position. When all the four knife edges are blunt, you can remove the
current knife revolver and install a new knife revolver that is pre-set using a
setting jig. The knife revolver thus helps to reduce the time required for a knife
changeover. During cutting, the knife revolver is locked in position by the
stopper (5). When the machine is not producing products, the knife revolver
unit can be secured by a cover.

5 34 2
Fig. 3-7 Wall length cutting station

1. Revolver-type cutting unit

2. Knife revolver
3. Knife
4. Spacer roll
5. Stopper
6. Pressure roller

A pressure roller (6) at the wall length cutting station helps to support the
mandrel during the cutting process and also pushes the product (7) on the
mandrel (8) towards the knife to ensure a clean cut through out the
circumference of the product. Adjustments are provided to properly position
the pressure roller relative to the product. The pressure roller is driven by a
servomotor.

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3 - Description of the machine
Machine overview
De-burring station

3
8

Fig. 3-8 Pressure roller at the wall length cutting station

7. Product
8. Mandrel

3.2.8 De-burring station

At station 5 of the turret, a de-burring unit removes any sharp edges along the
cutting line of the product. The de-burring unit consists of a steel roller (1) which
squeezes the product edge against the rotating mandrel and thereby flattens
out any sharp edges or burrs that are formed during cutting.

Fig. 3-9 De-burring unit

1. Steel roller

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3 - Description of the machine
Machine overview
Brush segment

3.2.9 Brush segment

Between stations 4 and 15, a brush segment (1) prevents the scrap end-ring
formed after wall length cutting from moving inwards and out of reach of the
stripper plates at stations 4 and 15.

1
Fig. 3-10 Brush segment

1. Brush segment

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3 - Description of the machine
Machine overview
Mandrel drive and brake systems

3.2.10 Mandrel drive and brake systems

The mandrels are driven for cutting and brushing operations by a motor (1)
through a flat belt (2). The flat belt transmits the motor torque by friction applied
on the mandrel bushings behind the turret.The mandrel drive belt is in contact
with the mandrels from stations 3 to 8.

2
3

15
14 16

13 1

12 2

11 3

10 4

9 5

8 6
7

Fig. 3-11 Mandrel drive and brake system

1. Mandrel drive motor

2. Mandrel drive belt
3. Mandrel brake belt

The mandrel brake system consists of a fixed brake belt (3). The mandrel brake
belt stops the mandrel rotation before the take-off operation at stations 12, 13,
and 14. The brake belt is in contact with the mandrels from stations 9 to 2.

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3 - Description of the machine
Machine overview
Brushing stations

3.2.11 Brushing stations

The brushing units (1) at stations 6 and 8 brush the product surface to facilitate
the subsequent base coating and printing operations.The product brushing
unit uses a circular wire brush roller driven by a separate motor. The brush
roller (2) can also reciprocate along the mandrel. The reciprocating motion of
the brush roller can be switched ON or OFF. The reciprocating motion of the
brush roller is driven by separate servomotor through cams and linkages. The
product brushing unit has a No-Product-No-Brush function which retracts the
brush roller away from the mandrel if the mandrel is empty.

A pressure roller (3) installed at each brushing station presses the product
against the mandrel and prevents the product from slipping on the mandrel
during the brushing operation.

Fig. 3-12 Brushing station (Brushing station 2 shown)

1. Brushing unit
2. Brush roller
3. Pressure roller

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3 - Description of the machine
Machine overview
Take-off unit

3.2.12 Take-off unit

The take-off unit (1) transfers the finished products to the outfeed chain. The
take-off function takes place simultaneously at stations 12, 13, and 14. The
products are gripped by the product grippers (2) of the take-off unit and placed
on the chain pegs of the outfeed chain. The take-off unit is driven by the main
drive through double cams, linkages, timing belts and pulleys.

Fig. 3-13 Take-off unit

1. Take-off unit
2. Product gripper

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3 - Description of the machine
Machine overview
Stripper unit

3.2.13 Stripper unit

The stripper unit (1) removes the scrap end-rings, which are cut off from the
product walls, before new products are loaded on the mandrels. This device
is mechanically synchronised with the turret and makes a stroke motion along
the length of the mandrel. During the outward stroke, the first stripper plate
(2) pushes the end-ring up to the retaining brush (4). The second stripper plate
(3) pushes the end-ring into a scrap channel (5). During its inward stroke, the
stripper plates are lifted up to let the mandrel pass during the indexing of the
turret.

3
2

4
5
Fig. 3-14 Stripper unit

1. Stripper unit
2. First stripper plate
3. Second stripper plate
4. End ring retaining brush

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3 - Description of the machine
Machine overview
Scrap extraction unit (Cyclone unit)

3.2.14 Scrap extraction unit (Cyclone unit)

A scrap channel (1) is installed at station 15 to collect the scrap end-rings (after
wall length cutting). From the scrap channel, the scrap end-rings and
aluminium chips are transferred to an external scrap separation unit (Cyclone
unit) at the rear of the machine through vacuum suction.

The safety flap (2) with sensor (3) on the scrap channel opens in case a product
passes through the scrap channel. The machine sounds an alarm and goes
to a fast stop. The product must be manually removed and the machine reset
before resuming production.

Fig. 3-15 Scrap extraction unit

1. Scrap channel
2. Safety flap
3. Sensor

3.2.15 Dust collection ducts

During the cutting, brushing, and bottom forming operations, aluminium dust
is generated. In order to keep the machine clean during operation, several dust
collection ducts are provided in the machine. These ducts are connected to
an external wet dust separator.

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3 - Description of the machine
Technical data
Utilities data

3.3 Technical data

3.3.1 Utilities data

Electrical connection

Main power supply 3 X 400V AC + N + PE, 50Hz

Other power systems/voltages
have to be arranged with
PackSys Global.

Signal voltage and control 24V DC

Permissible voltage deviation ±5%

Power consumption 45 kW

Main drive 20 kW, 2000 rpm, Servomotor

Feeding drum drive 2.5 kW, 3000rpm, Servomotor

Mandrel drive 5kW, 2570rpm

Outfeed chain drive 0.82 kW, 3000 rpm, Servomotor

Cutting station X-axis drive 0.10 kW, 6000rpm, Servomotor

Cutting station Y-axis drive 0.10 kW, 6000rpm, Servomotor

Pressure roller drive - Cutting station 0.82 kW, 3000 rpm, Servomotor

Brushing station (I & II) roller drive 5kW, 2570rpm

Brushing station (I & II) oscillation drive 0.82kW, 3000rpm

Pressure roller drive - Brushing station (I 0.82 kW, 3000 rpm, Servomotor
& II)

Press transfer conveyor drive 0.82 kW, 3000 rpm, Servomotor

Vacuum pump for press transfer 2.2 kW, 2805 rpm

conveyor

Vacuum pump for feeding drum 2.2 kW, 2805 rpm

Vacuum pump for turret 2.2 kW, 2805 rpm

Scrap extraction unit (Cyclone) drive 3 kW, 2920 rpm

Oil pump drive 0.37 kW, 1375 rpm

Pneumatic connection

Inlet pressure Minimum 6 bar

Air purity Absolute filtration 100µm oil

free, moisture free

Air consumption 70 Nm3/h

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3 - Description of the machine
Technical data
Machine data

3.3.2 Machine data

Machine data

No. of mandrels 16

L x B x H of machine 5190 x 3105 x 2591 mm

Net weight 7500 kg

3.3.3 Product data

End product

Can diameter range 45.0 - 66.0 mm

Trimmed can length. 90.0 - 260.0 mm

Machine speed Up to 200 products per minute,

steplessly adjustable.

3.3.4 Chain data

Transport chain

Chain pitch (P) 19.05 mm (P = 3/4")

Chain peg pitch (6P) 114.3 mm (6 x 3/4")

Chain peg length 310 mm

Chain peg diameter 5 mm

3.3.5 Environmental conditions

The machine must be installed and protected in an approved industrial type
building. The machine can be used only within these environmental limits:

Environmental limits

Atmosphere at the installation site Free of dust, corrosive agents

and gases. No direct exposure
to sea breeze.

Elevation of the installation site Max. 1000 m above sea level

Room temperature range +15°C to +40°C

Max. average 35°C

Room temperature variations Max. 20°C in 24 hours

Max. 6°C in 1 hour

Relative humidity Max. 75% (average value)

without dewing
Max. 90% at 20°C
Max. 50% at 40°C

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3 - Description of the machine
Technical data
Noise level

3.3.6 Noise level

The Zelos machine emits noise of up to 85dB during its operation.

CAUTION
High noise level.
Risk of damage to hearing due to constant exposure to high noise
levels
– Use hearing protection.

3.3.7 Location of the name plate

PackSys Global (Thailand) Ltd

119, Moo 5 Soi 12, Highway No. 36,
Tumbol Makhamkoo,
Amphur Nikhom Phattana,
Rayong Province 21180, Thailand

* 1
* 2
* 3
Made in Thailand

Fig. 3-16 Location of the name plate

1. Machine model / name

2. Machine no.
3. Year of manufacture

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3 - Description of the machine
Technical data
Machine layout

3.3.8 Machine layout

 




Fig. 3-17 Machine layout

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3 - Description of the machine
Technical data
Machine layout

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3-20 Zelos Operating Manual V1.0

4 - Transport and Installation
Transport

4 Transport and Installation

This chapter gives you information about the general precautions and correct
procedures to follow when a PackSys Global machine is transported into and
installed at your installation site.

4.1 Transport
The machine is safely packed in strong wooden crates for surface transport,
sea transport or air freight. The machine is supplied in assembled condition.
Additional or optional equipment are supplied in different crates or pallets.

NOTICE
Obey all the applicable mandatory safety and accident prevention
rules during transport.

4.1.1 Unpacking and inspection

It is recommended to get the wooden crates containing the machinery under
the roof of the installation site and near its assigned position before unpacking.

▪ Open the top cover of the wooden box and then remove the side walls.
▪ Remove the packing materials and make sure that the machine is correctly
attached to the base pallet.
▪ Keep the delivery papers in a safe place.
▪ Visually examine the machine for any damage.

NOTICE
If the machine is damaged on arrival, inform PackSys Global and the
carrier immediately. If necessary, consult an independent expert
immediately. Take necessary photographs of the damaged area and
mail it to PackSys Global as a first hand information.

4.1.2 Lifting the machine

Obey all the precautions given in the section below before lifting the machine
or its components.

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4 - Transport and Installation
Transport

DANGER
Heavy lifted load.
Risk of death or serious injury if incorrect lifting equipment or
incorrect lifting procedures are used.
– Stay clear of lifted loads.
– Use correct and applicable lifting equipment.
– Let only approved personnel do the lifting procedures.

NOTICE
PackSys Global disclaims all liabilities for any damage to the
machinery caused by incorrect lifting procedures. Use only correct
lifting equipment and let only approved personnel do these tasks.

Lifting and positioning the machine within the factory

The procedure for lifting the machine is as follows.

NOTICE
Make sure that the installation site is large enough to permit safe
procedures during installation.
We recommend that you use an expert service provider with the
necessary know-how and equipment to lift or move PackSys Global
machinery in the installation site.

Prerequisites ▪ The machine is disconnected from its pneumatic and electrical supply.
▪ The machine is isolated from its peripherals or from its upstream and
downstream machine.
▪ The front and side safety doors of the machine are removed.
▪ The location of the machine’s centre of gravity is known.
▪ The press transfer conveyor is un-installed from the machine.

Tools required ▪ A set of Allen keys and spanners.

▪ A crane or other hoisting equipment.
▪ Lifting brackets
▪ Lifting ropes or cables.
▪ Shackles
▪ Lifting bar

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4 - Transport and Installation
Transport

Procedure

1. Fix the four lifting brackets (1) at the respective positions of the machine
(See figure below).
5

3
2
4 1

Fig. 4-1 Lifting the machine

2. Attach the lifting cables (3) to the lifting brackets using the shackles (2).

3. Insert and tighten the pin (4) to secure the shackles to the lifting brackets.

4. Attach the other end of the lifting cables (3) onto the lifting beam (5).

5. Attach the cables of the lifting beam onto the hook of the crane/ hoisting
equipment.

Ensure that the hook of the crane is positioned exactly over the
centre of gravity of the machine.

6. Lift the machine off the ground.

7. Move the machine to the required position.

8. Set the machine down at its assigned position in the layout.

9. Level the machine by adjusting the levelling feet at the machine base.

■ End of the procedure.

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4 - Transport and Installation
Transport

4.1.3 Transporting the packed machine

Before transporting the machine, obey these precautions:

▪ Make sure that the machine is correctly attached and balanced on the
bottom plate of the pallet or crate.
▪ Visually examine each chain, anchor points and tie-down locations for
signs of damage.
▪ Inspect the machine and the shipping container for fluid leakages or loose
debris.
▪ Make sure that the crate / shipping container is correctly attached to the
transport vehicle.
▪ Obey all the applicable regulations about accident prevention and safety,
which are in force at this time.

4.1.4 Storing the machine

If the machine cannot be installed immediately and must be stored for a long
period until its installation, obey these precautions to give the machine
sufficient protection:

▪ Make sure that the machine is kept on its wooden pallet in a clean and
dry place under the roof.
▪ Put a cover or a protective film on the machine and use silica gel to give
the machine protection from dust and moisture.
▪ Use the wooden walls and covers to pack the machine again in its shipping
crate.

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4 - Transport and Installation
Installation

4.2 Installation
Prepare the place of installation (foundations) according to the erecting and
foundation plans supplied by PackSys Global. The equipment must be
installed on a level floor of sufficient load bearing capacity.

Obey all the precautions given in the section below before installing the
machine and its line components.

WARNING
Incorrect lifting equipment or procedures.
Risk of death or serious injury if incorrect lifting equipment or
incorrect lifting procedures are used.
– Use correct and applicable lifting equipment.
– Let only approved personnel do the lifting procedures.

NOTICE
PackSys Global disclaims all liabilities for any damage to the
machinery caused by incorrect lifting procedures. Use only correct
lifting equipment and let only approved personnel do these tasks.

NOTICE
Make sure that the installation site is large enough to permit safe
procedures during installation.
We recommend that you use an expert service provider with the
necessary know-how and equipment to lift or move PackSys Global
machinery in the installation site.

NOTICE
We recommend that all PackSys Global machines are installed and
started up at your installation site with hands-on support from
PackSys Global engineers.

4.2.1 Rust protection

Before the unit is started up, its rust protection must be removed with suitable
cleaning agents that are not harmful to the unit's technical safety nor a threat
to personal health.

4.2.2 Cooling system

In order to prevent damages caused by frost during transport and storage, the
coolant water must be emptied completely. Before start-up of the unit, the
cooling system must be refilled to capacity.

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4 - Transport and Installation
Installation

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5 - Operation
User interface

5 Operation
This chapter describes the functionality of each element of the user interface.
It also explains how to operate the machine by using the elements of the user
interface.

5.1 User interface

The machine is operated via an operating panel, which mainly consists of a
touch screen and push buttons. The operating interface also includes a hand-
held switch and a stylus.

5.1.1 Operating panel

1 2 3 4
Fig. 5-1 Operating panel

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5 - Operation
User interface

Elements / Signals Functions / Indications

Start push button 1 References the machine drive to its home
position. Pushing the [Start] button once
more starts the machine in Auto mode.

In the Inching mode, the [Start] button has to

be held to run the machine.

Indicator flashes The machine is ready to run in Auto mode.

Indicator ON The machine is running.

Indicator OFF The machine is not ready to run.

Stop push button 2 Stops the machine, when the machine is

running in Auto mode.

Indicator flashes The machine is ready to stop.

Indicator ON The machine is stopping.

Indicator OFF The machine has stopped.

Emergency stop 3 Stops the machine or the line immediately.

button Once the [E-Stop] button is activated, the
machine / line cannot be restarted unless the
[E-Stop] is released and reset.

Use the [E-stop] only in case of an

emergency. For a normal stoppage of the
machine / line, press the [Stop] button.

Reset push button 4 Acknowledges the alarm and mutes the

hooter when an alarm (error or event) occurs.

The [Reset] button has to be activated once

more after the error condition is no longer
valid.

Indicator flashes An alarm has occurred.

Indicator ON The alarm has been acknowledged.

Indicator OFF No alarm or the alarm has been cleared.

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5 - Operation
User interface

Elements / Signals Functions / Indications

Touchscreen 5 The touchscreen is used to set up and
operate the machine by means of using the
function keys and editing the machine
parameters on the various functional
screens displayed on the touchscreen panel.
Manual comply 6 The [Manual comply] switch is used to
switch (Dead override the door safety function in order to
man’s switch) allow fine adjustments on the machine by
keeping the safety door(s) open and the
machine active.

The switch has to be lightly pressed and held

with one hand, while operating the
touchscreen functions with the other hand.

Fully depressing the switch stops the

machine.

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5 - Operation
User interface

5.1.2 Signal tower

Machine status indicator

The signal tower on top of the machine raises audible and visual signals to
alert the user about the state of the machine.
Hooter The hooter raises audible alarm signals
depending on the alarm condition of the
machine:

1. Machine start:
The hooter raises an alarm when the
Start button is activated for the first
time for the machine drives to
reference. After the machine has
referenced, the [Start] button has to be
activated once again to run the
machine.
2. Error:
The hooter raises an alarm when the
machine stops due to an error.
3. Event:
The hooter raises an alarm when a
user intervention is required.

The hooter alarms in case of errors and

events are acknowledged and muted by
activating the [Reset] button just once.
Red The red signal lamp flashes when the
lamp machine stops due to an error.
Amber The amber signal lamp lights up and
lamp remains ON when a user intervention is
required. The machine stops if the warning
is not heeded.
Green The green signal lamp flashes when the
lamp machine is ready to start. The green light
remains ON during operation.

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5 - Operation
Screen structure

5.2 Screen structure

There are two types of screens in the user interface of the machine- Home
screens and the module screens.

The home screens display manual function keys, machine parameter fields
and helps to navigate to the various module screens of the machine. The
module screens display parameters and touch keys for the different modules
of the machine.

Certain functions/ modules are locked depending on the rights assigned to the
user or the machine status.

12 1 2 3 12

5
6
11
7

10 9
Fig. 5-2 Structure of the PRODUCTION: Home screen (for representation only)

15 16

13 14
Fig. 5-3 Structure of a module screen (for representation only)

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5 - Operation
Screen structure

System date Displays the system date and time.

and time (1)

Loaded recipe (2) Displays the name of the recipe currently loaded on the machine.

Errors (3) Displays the details of the currently pending alarms that must be cleared before
starting the machine.

Title bar (4) Displays the name of the active home screen, the selected machine module
and the colour of the active home screen.

User level (5) Sets/ Displays the active user level.

Tap this field to get a pop-up window. Select the required user level and the
required screen language and enter the correct password to log in with the
selected user level.

Fig. 5-4 Log-in window

Tap the Log off key to log out of the current user level.

Machine speed (6) Sets/ Displays the machine speed in products per minute (ppm).

Shift Graphically displays the total number of good products processed in the
counter (7) machine in the current shift. Tap this field to get a pop-up window with the
following parameters and touch keys:

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5 - Operation
Screen structure

Fig. 5-5 Pop-up window

Batch target:
Defines the production batch target, the total number of products to be
processed in the current batch.

Shift target:
Defines the shift target, the total number of products to be processed in the
current shift.

Resets all the counters in the PRODUCTION: Home screen. Tap and hold the
Reset key for 3 seconds. This function is accessible to Technician level users
only.

Navigation bar (8) Displays the five navigation keys to navigate to the five different home screens
– Production, Recipe, Alarm, Settings and Information screens. Access to the
home screens depends on the user rights.

Touch keys (9) These keys are used to check the functionality of single functions and to set
up the different machine modules. Access to these keys depends on the user
rights or the operating mode of the machine.

Machine Displays the general and most commonly used parameters for machine
parameters (10) operation. You can edit and save these parameters if you have the appropriate
user rights.

Machine graphic (11) Graphically displays the different modules of the machine. Tapping on the
different modules will navigate you to the different modules of the active home
screen.

Line overview (12) Opens a drop down page that displays the overview of the entire line.

Module screen (13) Displays the machine parameters and the touch keys for setting the respective
module of the machine.

Central graphic The read-only field of the central graphic layout displays the information related
layout (14) to the various modules.

Sub-navigation bar (15) Displays the different sub-navigation keys to navigate to the different available
module screens.

Home key (16) Navigates back to the currently active home screen.

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5 - Operation
Screen structure

5.2.1 Title bar

The title bar is divided into three sections. The first section (1) indicates the
active home screen while the second section (2) indicates the selected module
of the machine.

1 2

Fig. 5-6 Title bar

1. Active home screen

2. Selected machine module or recipe list

The title bar is displayed in different colours depending on the selected home
screen:

Colour Colour name Active home screen

Green PRODUCTION

Yellow RECIPE

Red ALARM

Blue SETTINGS

Mirrorcryl Green INFORMATION

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5 - Operation
Navigation keys

5.3 Navigation keys

Navigation keys are used to switch to the respective home screens -
Production, Recipe, Alarm, Settings and Information.

Following are the various navigation keys, their functions and the availability
of these keys under different user levels of login

User levels 1, 2, 3 mean Level 1 (Operator), Level 2 (Setter) and Level 3

(Technician) login respectively.

Production:
Displays the PRODUCTION home screen.
From this screen, you can go to the PRODUCTION screens of the other
modules and check the functions or edit the parameters of the individual
modules depending on the user level.

Recipe:
Displays the RECIPE: Home screen.
In the RECIPE: Home screen, you can create a new recipe as well as manage
and edit existing recipes. You can also navigate to the different machine
module screens and view/ edit the recipe parameters for the respective
machine modules.

Alarm:
Displays the ALARM: Current Alarm screen.
You can see the different alarm messages and errors that occurred in the
machine and remedies to clear the errors. From this screen you can also go
to the ALARM: Historical Alarm screen.

Settings:
Displays the SETTINGS: Hardware Active screen.
You can see the status of the different of the machine. From this screen you
can to the SETTINGS screens of the other modules and activate/ deactivate
the individual modules.

Information:
Displays the INFORMATION: Production Counter screen.
You can see the daily, weekly and total production statistics on this screen.
You can view or reset the production records, depending on user rights.
You can also go to the INFORMATION: Power monitoring screen.

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5 - Operation
Appearance of touch keys

5.4 Appearance of touch keys

The touch keys of the various screens appear in any of the following forms
depending on the actual state of the function:

Inactive:
The relevant function is INACTIVE.
Tapping the key will ACTIVATE the function.

Active:
The relevant function is ACTIVE.
Tapping the key will DEACTIVATE the function. The keys toggle the function
between ACTIVE and INACTIVE states.

Inactive blocked:
The function is INACTIVE and cannot be activated because function can not
be performed in this state of the machine or operation/movement is inhibited
because it is interfering with any other part of the machine.

Active blocked:
The function is ACTIVE and cannot be deactivated because function can not
be performed in this state of the machine or operation/movement is inhibited
because it is interfering with any other part of the machine.

5.5 Common touch keys

Following are the different touch keys that commonly appear throughout the
screens:

ON / OFF key:
Turns ON or OFF the respective function in the Auto mode.
Either of the two status indicators ‘I’ (green) and ‘O’ (red) on the key will glow
to indicate if the function is ON or OFF. Switch ability between ON and OFF
depends on the operating mode of the machine and the user level.

More key:
Shows the additional parameters and touch keys related to a function that are
otherwise hidden from the screen.
You can then edit these additional – parameters or use the touch keys to
perform additional functions. Tap anywhere on the screen to hide the additional
parameters and touch keys.

Home key:
Navigates back to the currently active Home screen.

Scroll keys (Option):

Scrolls through the different module screens of the currently active Home
screen.

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5 - Operation
Setting the parameter values

5.6 Setting the parameter values

To set the value of a parameter:

1. Tap the field displaying the parameter value which needs to be edited. (An
on-screen keypad will pop up).
2. Key in the new value by using the on-screen keypad.
3. Tap the [Enter] key to input the edited value. (The on-screen keyboard will
disappear and the new value will be displayed in the parameter field).

5.7 User levels

The different user levels for operating, setting and maintaining the machine
are described as below:

Operator level After the machine is switched ON, the user need to enter the password for the
(Level 1) respective user level. The operator level is a password-protected level that
allows the user to start and work on the machine. In this level, it is not possible
to change any parameters or settings.

Supervisor/Setter level This password-protected level allows the user to change certain machine
(Level 2) parameters, load a recipe and configure the machine functions. Access to this
level is given only to supervisor/setter trained by PackSys Global.

Technician level This password-protected level allows the user to change even more machine
(Level 3) settings and configurations as compared to Level 2 access. Access to this level
is given only to supervisors and technicians trained and certified by
PackSys Global.

5.8 Line overview

The line overview appears when you tap the line overview icons (1) on the top-
left or top-right of any screen. Tap anywhere on the line overview to close it.

1 1

2 3

DP- III DP- II DP- I

8
7

5
6 9

4
10
11
Can Accu- CMA - II PMA CMA - I Accu-IBO IBO JLD Accu-PW PW Zelos Press
Necker DP-III

Fig. 5-7 Line overview

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Line overview

Line overview icon (1) Displays the drop down page showing the line overview.

Notification window (2) Displays the different notifications during machine operation.

Current alarm Displays the list of active alarms in the current machine.
window (3)

Machine status Indicates the different statuses of the machine as listed below:
indicator (4)
▪ Red indicates that the machine has stopped. The time for which the
machine is stopped is also displayed on the red bar.
▪ Green indicates that the machine is running and processing cans.
▪ Grey indicates that the machine is idling (not processing cans).

Warning The yellow warning indicator indicates that some warnings exist in the machine
indicator (5) and the machine needs to be checked.

Machine speed (6) Displays the speed of the machine.

Oven chamber Displays the temperature inside the oven chamber.

temperature (7)

Product counter (8) Displays the total number of products in the corresponding machine.

Fill percentage (9) Displays the fill percentage of the accumulator.

Sum of products (10) Displays the total sum of products between the current machine and the end
of the line (Necking machine).

Sum of Displays the total sum of scrap rate between the current machine and the end
scrap rate(11) of the line. The figure is the percentage of rejected products in relation to the
total products produced.

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Machine graphic – Zelos

5.9 Machine graphic – Zelos

The icons of the machine graphic on the home screens serve as short-cuts
to the screens of the corresponding machine module.They also indicate the
status (ON or OFF) of the different modules. The Zelos machine graphic has
the following icons:

1 2

4 3
Fig. 5-8 Zelos- Machine graphic

1. Turret and outfeed

2. Cutting
3. Brushing 1
4. Brushing 2

Tap the required icon on the machine graphic to go to the screen of the
corresponding machine module.

5.10 Sub-navigation bar

The sub-navigation bar on the screens have the following keys:

4 3 2 1 5
Fig. 5-9 Sub-navigation bar

1. Turret and outfeed

2. Brushing 1
3. Brushing 2
4. Cutting
5. Home key

Tap the required key on the sub-navigation bar to switch to the screen of the
corresponding module.

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Welcome Screen

5.11 Welcome Screen

When the machine is powered ON from the main electrical cabinet of the Zelos
(or the electrical cabinet of the front line if the Zelos machine is part of a
complete line), the Welcome screen appears.

Fig. 5-10 Welcome screen

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5.12 Production screens

5.12.1 PRODUCTION: Home screen
When you tap on the Welcome screen, the PRODUCTION: Home screen
appears.

Fig. 5-11 PRODUCTION: Home screen

The parameters and touch keys of the PRODUCTION: Home screen are as
follows:

Parameters of the PRODUCTION: Home screen

Actual speed [ppm]:
Displays the actual speed of the machine/ line in ppm.

Length [mm]:
Displays the set length of the product processed in the machine.

Diameter [mm]:
Displays the set diameter of the product processed in the machine.

Shift target [#]:

Displays the set total number of products to be processed in the current shift.

Shift good prod. [#]:

Displays the total number of good products processed in the machine in the
current shift.

Shift reject [#]:

Displays the total number of products rejected in the machine in the current
shift.

Batch target [#]:

Displays the set total number of products to be processed in the current batch.

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Batch good prod. [#]:

Displays the total number of good products processed in the machine in the
current batch.

Batch Reject prod. [#]:

Displays the total number of products rejected in the machine in the current
batch.

Press batch prod.[#]

Displays the set number of products processed on the Press machine in the
current batch.

Press reject prod.[#]

Displays the set number of products rejected from the Press machine.

Inching Speed [ppm]:

Defines and displays the inching speed of the machine / line for setup in
products per minute. This is the speed at which the machine will run in the
Inching mode. Use the ‘+’ and ‘-’ keys or type a value to set the required inching
speed.

Machine graphic
The icons of the machine graphic on the PRODUCTION: Home screen serve
as shortcuts to the PRODUCTION screens of the corresponding machine
modules.They also indicates the status (ON or OFF) of the different modules.

Refer to the section “Machine graphic” in this chapter for

information about the different icons on the machine graphic.

Tap the required icon on the machine graphic to go to the PRODUCTION

screen of the corresponding machine module.

Touch keys of the PRODUCTION: Home screen

Mandrel vacuum ON/OFF:
Turns ON or OFF the vacuum pump for the mandrel during setups or
maintenance.
User level:2, 3

Clean screen function ACTIVE:

Activates the clean screen function.
When you tap this key, the touch sensitivity of the touch screen is disabled for
a preset time interval. You can wipe the screen during this time without affecting
the elements on the screen.
User level: 1, 2, 3

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Inching mode ACTIVE:

Activates the Inching mode of the machine.
You can then press and hold the Start button to inch the machine for setups
or maintenance. The machine inches at the speed defined in the Inching speed
parameter.
When you release the Start button, the machine stops and the hooter gives
an audio signal for 9 seconds to indicate that the Inching mode is still active.
After 9 seconds, the inching mode is deactivated.
User level: 1, 2, 3

5.12.2 PRODUCTION: Turret and outfeed screen

To go to the PRODUCTION: Turret and Outfeed screen:

▪ Tap the Turret and Outfeed icon on the machine graphic of the
PRODUCTION: Home screen OR
▪ Tap the Turret and Outfeed key on the sub-navigation bar of any of the
PRODUCTION screens.

Fig. 5-12 PRODUCTION: Turret and Outfeed screen

The parameters and touch keys of the PRODUCTION: Turret and Outfeed
screen are as follows:

Parameters of the PRODUCTION: Turret and Outfeed screen

Manual [ppm]:
Defines the jog speed of the machine turret for setup (in products per minute).

Alarm Series:
Defines the number of products that have to be consecutively ejected to force
the machine to stop.
For example, if you assign a value of 10, the machine will stop when 10 products
are ejected in succession.
An entry of 0 will deactivate this function.

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Production screens

Central graphic layout:

The fields on the central graphic layout display the actual positions of the
feeding drum drive (right), turret drive (centre) and the outfeed chain drive (left).

Touch keys of the PRODUCTION: Turret and Outfeed screen

Press transfer conveyor JOG:
Jogs the press transfer conveyor at the speed set in the [Manual] parameter.
The press transfer conveyor moves as long as the key is held.
User level: 2, 3

More key:
The More key next to the Press transfer conveyor JOG key displays a pop-
up window with the following additional parameters:

Fig. 5-13 Pop-up window

Manual [ppm]:
Defines the jog speed for the press transfer conveyor.

Offset [°]:
Defines a timing offset to the press transfer conveyor drive to fine tune the
transfer of products from the intermediate drum to the feeding drum.

Reject air blow ON [°]:

Defines the position (in degrees) at which the airblow to reject a product at
the product rejection station is activated (ON).
Adjust this value to fine-tune the start time of the rejection airblow for proper
rejection of products.

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If the value is set too less, the airblow will start earlier than the arrival
of the product at the rejection station.
If the value is set too high, the airblow will be delayed and the
product will not be rejected in time.

Reject air blow OFF [°]:

Defines the position (in degrees) at which the airblow to reject a product at
the product rejection station is deactivated (OFF).
Adjust this value to fine-tune the end time of the rejection airblow for proper
rejection of products.

If the value is set too less, the airblow will be switched OFF earlier
and the product will not be rejected.
If the value is set too high, the airblow will remain ON for a longer
time and the succeeding products may also get rejected.

Actual pos. [°]:

Displays the actual position of the press transfer conveyor drive.

Sample air ON [°]:

Defines the position (in degrees) at which the airblow to eject a product at the
sample ejection position is activated (ON).
Adjust this value to fine-tune the start time of the airblow for proper ejection
of products.

If the value is set too less, the airblow will start earlier than the arrival
of the product at the sample ejection station.
If the value is set too high, the airblow will be delayed and the
product will not be rejected in time.

Sample air OFF [°]:

Defines the position (in degrees) at which the airblow to eject a product at the
sample ejection position is deactivated (OFF).
Adjust this value to fine-tune the end time of the airblow for proper ejection
of products.

If the value is set too less, the airblow will be switched OFF earlier
and the product will not be ejected.
If the value is set too high, the airblow will remain ON for a longer
time and the succeeding products may also get ejected.

Press transfer conveyor REFERENCE

References the press transfer conveyor drive axis to its home
position when the key is tapped and held.
User level: 2, 3

Conveyor vacuum ON/OFF:

Turns ON or OFF the vacuum pumps for the transfer drum,
intermediate drum and the feeding drum during setup and
maintenance.
User level:2, 3

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Conveyor REJECT MANUAL:

Blows off products at the product rejection point on the conveyor.
User level: 2, 3

Feeding drum CYCLE:

Jogs the feeding drum by one cycle at the speed set in the [Manual] parameter.
The feeding drum will run one cycle and then stop.
User level: 2, 3

More key:
The More key next to the Feeding drum CYCLEkey displays a pop-up window
with the following additional parameters:

Fig. 5-14 Pop-up window

Manual [ppm]:
Defines the jog speed for the feeding drum.

Offset [°]:
Defines a position offset for the feeding drum drive to fine-tune the transfer
of products from the feeding drum to the turret.

Feeding drum REFERENCE:

References the feeding drum drive axis to its home position.
User level: 2, 3

Mandrel vacuum ON/OFF:

Turns ON or OFF the vacuum pump for the mandrel during setup or
maintenance.
User level:2, 3

Turret JOG FORWARD:

Jogs the machine turret at the speed set in the [Manual] parameter.
The turret will move only as long as this key is held.
User level: 2, 3

More key:
The More key next to the Turret JOG FORWARD key displays a pop-up
window with the following additional touch keys:

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Fig. 5-15 Pop-up window

Lubrication pump ON/OFF:

Turns ON or OFF the lubrication pump of the machine.
User level: 2, 3

Mandrel exchange ON/OFF:

Activates the mandrel exchange function in Setup mode.
User level: 2, 3

Turret INDEX CYCLE:

Indexes the machine turret by one cycle at the speed set in the
[Manual] parameter.
User level: 2, 3

Turret REFERENCE:
References the machine turret drive axis to its home position when
this key is tapped and held.
The drive axis is referenced automatically when the machine is started in the
Auto mode.
User level: 2, 3

Manual [ppm]:
Defines the jog speed for the turret.

Turret JOG DEFINED POSITION:

Jogs the turret to the defined position(s) in one shot or step-by-step modes.
User level: 2, 3

More key:
The More key next to the Turret JOG DEFINED POSITION key displays a
pop-up window with the position list and the following additional parameters
and touch keys:

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Production screens

Fig. 5-16 Pop-up window

Position list:
Displays the list of predefined positions at which the turret can be jogged to.
Tap on the positions to add or edit the different positions in the list.

Turret Pos. [°]:

Displays the actual position of the turret.

One shot mode:

Activates the One shot mode of the Turret jogging function. In the One shot
mode, the turret can be jogged to a selected position (0 to 360 °) in the list.
Select the One shot mode on the pop-up window, and then select the required
position from the list. Tap and hold the Turret JOG DEFINED POSITION key.
The turret stops when the selected position is reached. If you tap and hold the
Turret JOG DEFINED POSITION key again, the turret jogs and stops at the
same position again.

Step by step mode:

Activates the step-by-step mode of the Turret jogging function. In the Step-
by-step mode, the turret can be jogged to multiple positions (0 to 360°) one
after the other in sequence. Select the Step-by-step mode on the pop-up
window, and select the required positions from the list. Tap and hold the Turret
JOG DEFINED POSITION key. The turret stops when the first selected
position is reached. Tap and hold the Turret JOG DEFINED POSITION key
again, the turret jogs and stops at the next selected position.

Turret CURRENT POSITION:

Indicates the current position of the turret in the turret jogging
function.
User level: 2, 3

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Product REJECT MANUAL:

Blows all products off the chain at the product rejection station as long as the
key is active (at manual command, whenever needed).
User level:1, 2, 3

More key:
The More key next to the Product REJECT MANUAL key displays a pop-
up window with the following additional parameters:

Fig. 5-17 Pop-up window

Reject at start [prod]:

Defines the number of products to be rejected after a fresh start up or restart
of the machine.

Reject Offset / Reject shift pos [prod.]:

Defines an offset value (between -3 and +3) to fine-adjust the rejection of
products at the product rejection station.

Reject On [°]:
Defines the position (in degrees) at which the airblow to reject a product at
the product rejection station is activated (ON).
Adjust this value to fine-tune the start time of the rejection airblow for proper
rejection of products.

If the value is set too less, the airblow will start earlier than the arrival
of the product at the rejection station.
If the value is set too high, the airblow will be delayed and the
product will not be rejected in time.

Reject Off [°]:

Defines the position (in degrees) at which the airblow to reject a product at
the product rejection station is deactivated (OFF).
Adjust this value to fine-tune the end time of the rejection airblow for proper
rejection of products.

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Production screens

If the value is set too less, the airblow will be switched OFF earlier
and the product will not be rejected.
If the value is set too high, the airblow will remain ON for a longer
time and the succeeding products may also get rejected.

Outfeed chain JOG

Jogs the outfeed chain at the speed set in the [Manual] parameter. The outfeed
chain will run as long as this key is held.
User level: 2, 3

More key:
The More key next to the Outfeed chain JOG key displays a pop-up window
with the following additional parameters:

Fig. 5-18 Pop-up window

Manual [ppm]:
Defines the jog speed of the outfeed chain.

Offset [°]:
Defines a timing offset for the outfeed chain drive to fine-tune the transfer of
products from the take-off unit to the outfeed chain.

Stop position [°]:

Defines the stop position of the machine outfeed chain.

Actual Pos. [°]:

Displays the actual position of the outfeed chain drive.

Chain Lubrication:
Activates the chain lubrication function in the Manual or Automatic modes.
User level: 1, 2, 3

Cycles [#]:
Defines the number of chain lubrication cycles to be performed during the
automatic chain lubrication function. If you enter a value of 1, the entire chain
length will be lubricated once (one cycle). If you enter a value of 2, the entire
chain length will be lubricated twice (two cycles).

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Pause time [hr]:

Defines the time (in hours) for which the lubricant pump will remain OFF after
the number of lubricant pulses set in the parameter [Cycles] is sprayed onto
the chain.

Outfeed chain REFERENCE:

References the outfeed chain drive axis to its home position.
User level: 2, 3

Product gripper ON/OFF:

Activates or deactivates the product grippers/ suction pads of the take-off unit.
User level: 2, 3

More key near the Product gripper ON/OFF key:

The More key next to the Product gripper ON/OFF key displays a pop-up
window with the following additional parameters and touch keys.

Fig. 5-19 Pop-up window

Cycle position [°]:

Displays the actual position of the take-off cycle (0 to 360°).

Take off 1 on [°]:

Defines the position (in degrees) at which the product gripper 1 of the take-
off unit is activated (ON). This is the position in the take-off cycle (0 to 360°)
at which the product is gripped by the product gripper 1.
Adjust this parameter to fine-tune the transfer of product from the mandrel to
the product gripper 1.

Take off 1 off [°]:

Defines the position (in degrees) at which the product gripper 1 of the take-
off unit is deactivated (OFF). This is the position in the take-off cycle (0 to 360°)
at which the product is released by the product gripper 1.
Adjust this parameter to fine-tune the transfer of product from the product
gripper 1 to the outfeed chain.

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Production screens

Take off 2 on [°]:

Defines the position (in degrees) at which the product gripper 2 of the take-
off unit is activated (ON). This is the position in the take-off cycle (0 to 360°)
at which the product is gripped by the product gripper 2.
Adjust this parameter to fine-tune the transfer of product from the mandrel to
the product gripper 2.

Take off 2 off [°]:

Defines the position (in degrees) at which the product gripper 2 of the take-
off unit is deactivated (OFF). This is the position in the take-off cycle (0 to 1080°)
at which the product is released by the product gripper 2.
Adjust this parameter to fine-tune the transfer of product from the product
gripper 2 to the outfeed chain.

Take off 3 on [°]:

Defines the position (in degrees) at which the product gripper 3 of the take-
off unit is activated (ON). This is the position in the take-off cycle (0 to 1080°)
at which the product is gripped by the product gripper 3.
Adjust this parameter to fine-tune the transfer of product from the mandrel to
the product gripper 3.

Take off 3 off [°]:

Defines the position (in degrees) at which the product gripper 3 of the take-
off unit is deactivated (OFF). This is the position in the take-off cycle (0 to 1080°)
at which the product is released by the product gripper 3.
Adjust this parameter to fine-tune the transfer of product from the product
gripper 3 to the outfeed chain.

Mand. airblowOn [°]:

Defines the position (in degrees) at which the airblow to the mandrels (at the
unloading station) is activated (ON). This is the position in the take-off cycle
(0 to 1080°) after the product is just gripped by the product gripper. The airblow
through the mandrels help the product take-off function.
Adjust this parameter to fine-tune the transfer of product from the mandrel to
the product grippers.

Mand. airblowOff [°]:

Defines the position (in degrees) at which the airblow to the mandrels (at the
unloading station) is deactivated (OFF). This is the position in the take-off cycle
(0 to 1080°) after the product is fully removed from the mandrels by the product
grippers.

Mandrel airblow ON/OFF:

Turns ON or OFF the airblow to the mandrels at the unloading
station.
User level: 2, 3

Scrap extraction unit ON:

Activates the scrap extraction unit (Cyclone) in Setup mode.
User level: 2, 3

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More key near the Scrap extraction unit ON key:

The More key next to the Scrap extraction unit ON key displays a pop-up
window with the following additional parameters and touch keys.

Fig. 5-20 Pop-up window

Cyclone dump [Prod]

Defines the number of products after which the flap of the cyclone unit opens
to dump the scrap from the unit (to a collection bin).

Cyclone dump ON:

Opens the flap of the cyclone unit to dump the scrap from the unit.
User level: 1, 2, 3

Line mode ON:

Activates the Line mode or individual machine mode. If the Line mode is
activated and if the Press machine is ready for operation, the front line can
be started.
User level: 2, 3

Extrusion ON:
Switches ON/OFF the press machine.To operate the front line together with
the Press machine, the Line mode ON and Extrusion ON keys must be
activated.
User level: 2, 3

More key near the Extrusion ON key:

The More key next to the Extrusion ON key displays a pop-up window with
the following additional parameters:

Fig. 5-21 Pop-up window

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Production screens

Press offset [°]

Defines a timing offset for the outfeed starwheel of the Press machine to fine-
tune the transfer of products from the Press machine to the conveyor.

Press engage [°]

Sync speed [°]

Defines the speed at which the machines move during synchronization.

5.12.3 PRODUCTION: Brushing 1 screen

To go to the PRODUCTION: Brushing 1 screen:

▪ Tap the Brushing icon on the machine graphic of the PRODUCTION:

Home screen OR
▪ Tap the Brushing key on the sub-navigation bar of any of the
PRODUCTION screens.

Fig. 5-22 PRODUCTION: Brushing 1 screen

The parameters and touch keys of the PRODUCTION: Brushing 1 screen

are explained below:

Parameters of the PRODUCTION: Brushing 1 screen

Mandrel speed [rpm]:
Defines the speed of the mandrel in rpm.

Actual speed [rpm]:

Displays the actual speed of the mandrel in rpm.

Brush 1 speed [rpm]:

Defines the speed of the brush 1 roller in rpm.

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Touch keys of the PRODUCTION: Brushing 1 screen

Brush 1 On/Off:
Activates the brushing 1 unit in the Auto mode.
User level: 1, 2, 3

Brush 1 clean On/Off:

Activates the brush 1 cleaning function (by the grindstone) in the Auto mode.
User level: 1, 2, 3

Brush 1 oscillate On/Off:

Activates the oscillating function of the brush 1 in the Auto mode.
User level: 1, 2, 3

Brush 1 motor On/Off:

Turns On or Off the brush motor at the brushing station.
User level:2, 3

More key:
The More key next to the Brush 1 motor On/Off key displays a pop-up window
with the following additional parameters and touch keys.

Fig. 5-23 Pop-up window

Clean cycle:
Defines the number of products to be processed (between 100 and 9999)
before the brush 1 will be cleaned by the grindstone.

Actual speed:
Displays the actual speed of the brush 1 roller.

Brush 1 speed:
Defines the speed of the brush 1 roller during operation (in rpm).

Standby speed:
Defines the speed of the brush roller in the standby position (in rpm).

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Brush 1 On [°]:
Defines the position in the machine cycle (from 0 to 360°) at which the
brushing 1 unit moves forward to brush products.

Brush 1 Off [°]:

Defines the position in the machine cycle (from 0 to 360°) at which the
brushing 1 unit retracts to idle position.

Brush 1 cleaning Cycle:

Runs one cycle of the brush 1 cleaning function.
User level:2, 3

Brush 1 cleaning Left/Right:

Moves the brush 1 cleaning grindstone left or right (along the length
of the brush 1 roller) in the Setup mode.
User level:2, 3

Brush 1 cleaning Engage:

Engages the brush 1 cleaning grindstone with the brush 1 roller in
the Setup mode.
User level:2, 3

Move Brush 1 to Brushing pos.:

Moves the brush 1 to its brushing position during a setup or
maintenance procedure.
User level:2, 3

Brush 1 oscillation Jog:

Jogs the brush roller oscillation drive in the Setup mode. The brush roller
oscillates at the speed set in the [Manual] parameter.
User level:2, 3

More key:
The More key next to the Brush 1 oscillation Jog key displays a pop-up
window with the following additional parameters and touch keys.

Fig. 5-24 Pop-up window

Manual [ppm]:
Defines the speed of oscillation of the brush 1 roller.

Actual pos. [°]:

Displays the actual position of the brush 1 roller oscillation drive.

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Brush 1 oscillation REFERENCE:

References the brush 1 roller oscillation drive axis to its home
position.
User level:2, 3

Pressure roller JOG:

Jogs the pressure roller drive in the Setup mode. The pressure roller rotates
at the speed set in the [Manual] parameter.
User level:2, 3

More key:
The More key next to the Pressure roller JOG key displays a pop-up window
with the following additional parameters and touch keys.

Fig. 5-25 Pop-up window

Speed adjust [rpm]:

Defines the adjustment speed of the pressure roller relative to the mandrel
speed.

Roller diameter [mm]:

Defines the diameter of the pressure roller.

Manual [rpm]:
Defines the speed of the pressure roller.

Actual speed [rpm]:

Displays the actual speed of the pressure roller.

Actual torque [Nm]:

Displays the actual torque of the pressure roller.

Pressure roller Activate:

Activates the pressure rollers at the brushing and cutting stations.
User level:2, 3

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Wet dust separator On/Off:

Turns On or Off the wet dust separator.
User level:2, 3

Wet dust separator Water On/Off (Option):

Turns On or Off the water supply to the wet dust separator.
User level:2, 3

5.12.4 PRODUCTION: Brushing 2 screen

To go to the PRODUCTION: Brushing 2 screen:

▪ Tap the Brushing icon on the machine graphic of the PRODUCTION:

Home screen OR
▪ Tap the Brushing key on the sub-navigation bar of any of the
PRODUCTION screens.

Fig. 5-26 PRODUCTION: Brushing 2 screen

The parameters and touch keys of the PRODUCTION: Brushing 2 screen

are explained below:

Parameters of the PRODUCTION: Brushing 2 screen

Mandrel speed [rpm]:
Defines the speed of the mandrel in rpm.

Actual speed [rpm]:

Displays the actual speed of the mandrel in rpm.

Brush 2 speed [rpm]:

Defines the speed of the brush 2 roller in rpm.

Touch keys of the PRODUCTION: Brushing 2 screen

Brush 2 On/Off:
Activates the brushing 2 unit in the Auto mode.
User level: 1, 2, 3

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Brush 2 clean On/Off:

Activates the brush 2 cleaning function (by the grindstone) in the Auto mode.
User level: 1, 2, 3

Brush 2 oscillate On/Off:

Activates the oscillating function of brush 2 in the Auto mode.
User level: 1, 2, 3

Brush 2 motor On/Off:

Turns On or Off the brush motor at the brushing station.
User level:2, 3

More key:
The More key next to the Brush 2 motor On/Off key displays a pop-up window
with the following additional parameters and touch keys.

Fig. 5-27 Pop-up window

Clean cycle:
Defines the number of products to be processed (between 100 and 9999)
before the brush 2 will be cleaned by the grindstone.

Actual speed:
Displays the actual speed of the brush 2 roller.

Brush 2 speed:
Defines the speed of the brush 2 roller in rpm.

Standby speed:
Defines the speed of the brush roller in the standby position (in rpm).

Brush 2 On [°]:
Defines the position in the machine cycle (from 0 to 360°) at which the
brushing 2 unit moves forward to brush products.

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Brush 2 Off [°]:

Defines the position in the machine cycle (from 0 to 360°) at which the
brushing 2 unit retracts to idle position.

Brush 2 cleaning Cycle:

Runs one cycle of the brush 2 cleaning function.
User level:2, 3

Brush 2 cleaning Left/Right:

Moves the brush 2 cleaning grindstone left or right (along the length
of the brush 2 roller) in the Setup mode.
User level: 2, 3

Brush 2 cleaning Engage:

Engages the brush 2 cleaning grindstone with the brush 2 roller in
the Setup mode.
User level: 2, 3

Move Brush 2 to brushing pos.:

Moves the brush 2 to its brushing position during a setup or
maintenance procedure.
User level: 2, 3

Brush 2 oscillation Jog:

Jogs the brush roller oscillation drive in the Setup mode. The brush roller
oscillates at the speed set in the [Manual] parameter.
User level: 2, 3

More key:
The More key next to the Brush 2 oscillation Jog key displays a pop-up
window with the following additional parameters and touch keys.

Fig. 5-28 Pop-up window

Manual [ppm]:
Defines the speed of oscillation of the brush 2 roller.

Actual pos. [°]:

Displays the actual position of the brush 2 roller oscillation drive.

Brush 2 oscillation REFERENCE:

References the brush 2 roller oscillation drive axis to its home
position.
User level: 2, 3

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Production screens

Pressure roller Jog:

Jogs the pressure roller drive in the Setup mode. The pressure roller rotates
at the speed set in the [Manual] parameter.
User level: 2, 3

More key:
The More key next to the Pressure roller Jog key displays a pop-up window
with the following additional parameters and touch keys.

Fig. 5-29 Pop-up window

Speed adjust [rpm]:

Defines the adjustment speed of the pressure roller relative to the mandrel
speed.

Roller diameter [mm]:

Defines the diameter of the pressure roller.

Manual [rpm]:
Defines the speed of the pressure roller.

Actual speed [rpm]:

Displays the actual speed of the pressure roller.

Actual torque [Nm]:

Displays the actual torque of the pressure roller.

Pressure roller Activate:

Activates the pressure rollers at the brushing and cutting stations.
User level: 2, 3

Wet dust separator On/Off:

Turns On or Off the wet dust separator.
User level: 2, 3

Wet dust separator Water On/Off (Option):

Turns OnOn or Off the water supply to the wet dust separator.
User level: 2, 3

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Production screens

5.12.5 PRODUCTION: Cutting screen

To go to the PRODUCTION: Cutting screen:

▪ Tap the Cutting icon on the machine graphic of the PRODUCTION:

Cutting screen OR
▪ Tap the Cutting key on the sub-navigation bar of any of the PRODUCTION
screens.

Fig. 5-30 PRODUCTION: Cutting screen

The parameters and touch keys of the PRODUCTION: Cutting screen are
explained below:

Parameters of the PRODUCTION: Cutting screen

Product dia. [mm]:
Defines the diameter of the product. This parameter determines the distance
between the cutting tool and the product wall.

Dia. cut offset [mm]:

Defines the offset to the product diameter to fine-adjust the distance between
the cutting tool tip and the product wall.

Product length [mm]:

Defines the length of the product. The product will be cut to this length at the
cutting station.

Length cut offset [mm]:

Defines the offset to the cutting length to fine-adjust the cutting length of the
product.

Mandrel speed [rpm]:

Defines the speed of the mandrel at the cutting station.

Actual speed [rpm]:

Displays the actual speed of the mandrel at the cutting station.

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Production screens

Speed adjust [rpm]:

Defines an offset value to fine-adjust the speed of the pressure roller relative
to the mandrel speed.

Central graphic layout:

The read-only fields on the central graphic layout display the actual positions
of the drives for the cutting tool X (length) and Y (diameter) axes.

Touch keys of the PRODUCTION: Cutting screen

Cutting On/Off:
Activates the wall length cutting function in the Auto mode.
User level: 1, 2, 3

Knife change auto:

Activates the knife revolver index function in the Auto mode. The knife revolver
will index to the next knife position, after the number of products as defined
in the No. of products parameter are processed.
User level: 1, 2, 3

Cutting Test:
Tests the wall length cutting function in the Setup mode. All functions required
for wall length cutting are automatically activated.
User level: 2, 3

To test the wall length cutting:

1. Put a product on the mandrel at the cutting station.

2. Tap the Cutting Test key. All functions (Vacuum, mandrel rotation, Knife
movement) runs automatically.

3. Remove the product from the mandrel and check for cut quality.

Knife revolver Index Manual

Indexes the knife revolver to the next knife position.
User level: 2, 3

More key:
The More key next to the Knife revolver Index Manual key displays a pop-
up window with the following additional parameters.

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Production screens

Fig. 5-31 Pop-up window

No. of products [#]:

Defines the number of products to be cut after which, the knife revolver
automatically indexes to the next knife position. The number of products is
reset when the knife revolver is indexed.

Products counter [#]:

Displays the actual number of products cut by the current knife.

Ref knife num [#]:

Sets the knife number that is currently active. This is used during setup. Press
the Knife revolver Reference key after setting the knife number.

Act knife num [#]:

Displays the knife number that is currently active.

Knife revolver lock Release:

Releases the knife revolver lock.
User level: 2, 3

Knife revolver Reference:

References the knife revolver to its home position.
User level: 2, 3

More key:
The More key next to the Dia. cut offset parameter displays a pop-up window
with the following additional parameters and touch keys.

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Production screens

Fig. 5-32 Pop-up window

Actual pos. [mm]:

Displays the actual position of the cutting tool diameter axis drive.

Manual [mm/s]:
Sets the speed of the knife towards or away from the product during setup.

Cutting diameter axis Reference:

References the drive for the cutting tool diameter axis to its home
position.
User level: 2, 3

Cutting diameter axis Jog Forward:

Moves the cutting tool towards the product wall.
User level: 2, 3

Cutting diameter axis Jog backward:

Moves the cutting tool away from the product wall.
User level: 2, 3

More key:
The More key next to the Length cut offset parameter displays a pop-up
window with the following additional parameters.

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Production screens

Fig. 5-33 Pop-up window

Actual pos. [mm]:

Displays the actual position of the cutting tool length axis drive.

Manual [mm/s]:
Sets the speed of the knife along the product during setup.

Cutting length axis Reference:

References the drive for the cutting tool length axis to its home
position.
User level: 2, 3

Cutting length axis Jog Forward:

Moves the cutting tool towards the bottom of the product.
User level: 2, 3

Cutting length axis Jog Backward:

Moves the cutting tool towards the mouth of the product.
User level: 2, 3

Airblow On/Off:
Turns On or Off the airblow at the cutting station.
User level: 2, 3

Mandrel drive On/Off:

Turns On or Off the mandrel drive.
User level: 2, 3

Pressure roller Jog:

Jogs the pressure roller drive in the Setup mode. The pressure roller rotates
at the speed set in the [Manual] parameter.
User level: 2, 3

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Production screens

More key:
The More key next to the Pressure roller Jog key displays a pop-up window
with the following additional parameters and touch keys.

Fig. 5-34 Pop-up window

Speed adjust [rpm]:

Defines an offset value to fine-adjust the speed of the pressure roller relative
to the mandrel speed.

Roller diameter [mm]:

Defines the diameter of the pressure roller.

Manual [rpm]:
Defines the speed of the pressure roller.

Actual speed [rpm]:

Displays the actual speed of the pressure roller.

Actual torque [Nm]:

Displays the actual torque of the pressure roller.

Pressure roller Activate:

Activates the pressure rollers at the brushing and cutting stations.
User level: 2, 3

Cutting knife counter:

Displays the cutting knife counter window which displays the number of
products processed by each knife over a period of time.

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5 - Operation
Production screens

Fig. 5-35 Cutting knife counter

The navigation arrows can be used to scroll through the

knife counters for the older or newer set of dates.

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Recipe screens

5.13 Recipe screens

5.13.1 RECIPE: Home screen
Tap the Recipe Navigation key on any screen to go to the RECIPE: Home
screen.
The RECIPE screens are accessible to Setter and Technician level users only.

Fig. 5-36 RECIPE: Home screen

The elements of the RECIPE: Home screen are explained below:

Recipe list:
Shows the list of all the stored recipes with their Author and last edited dates.
The desired recipe can then be selected.

Touch keys:

NEW recipe:
Creates a new recipe. The values are taken from the currently active recipe.
An input window pops up for entry of a new recipe name.
User level: 2, 3

EDIT recipe:
Opens the selected recipe for editing.
User level: 2, 3

LOAD recipe:
Loads the selected recipe to the PLC.
User level: 2, 3

SEARCH recipe:
Searches the required recipe from the list of recipes.
When you tap this key, a pop-up window appears. Enter the recipe name or
the product diameter to search the required recipe. You can also search a
recipe by the date of its creation.
User level: 2, 3

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Recipe screens

Recipe INFO:
Shows information about the selected recipe.
User level: 2, 3

DELETE recipe:
Deletes the selected recipe.
User level: 2, 3

Page scroll keys:

Scrolls through the different pages of the current screen.
User level: 2, 3

Machine graphic:
The icons on the machine graphic on the RECIPE: Home screen serve as
shortcuts to the RECIPE screens of the corresponding machine modules.
They also indicate the status (ON or OFF) of the different modules.

Refer to the section “Machine graphic” in this chapter for

information about the different icons on the machine graphic.

Tap the required icon on the machine graphic to go to the RECIPE screen of
the corresponding machine module.

5.13.2 Common elements of the RECIPE screens

3 4 5
Fig. 5-37 Common elements of the RECIPE screens – for representation only

Active Recipe (1):

Shows the name of the recipe currently active (loaded) on the machine.

Selected Recipe (2):

Shows the name of the recipe selected from the Recipe: list on the RECIPE:
Home screen.

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Recipe screens

Machine Parameter (3):

Shows the different recipe parameters for the selected machine module.

Recipe Value (4):

Shows the different recipe parameter values stored in the Selected Recipe (2).
Pressing on the recipe value opens a pop up window to edit the values.

Current Value (5):

Shows the different recipe parameters values currently active on the machine.

COPY Recipe to Current:

Copies the parameter values in Recipe Value to the Current Value (machine).
The parameter values in Current Value are replaced by the values in the Recipe
Value.
User level: 2, 3

COPY Current to Recipe:

Copies the parameter values in the Current Value to the Recipe Value. The
parameter values in Recipe Value are replaced by the values in the Current
Value.
User level: 2, 3

SAVE recipe:
Saves the changes made to the parameter values in Recipe Value or Current
Value columns.
User level: 2, 3

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Recipe screens

5.13.3 RECIPE: Turret and Outfeed screen

To go to the RECIPE: Turret and Outfeed screen:

▪ Tap the Turret and Outfeed icon on the machine graphic of the RECIPE:
Home screen OR
▪ Tap the scroll keys on any of the RECIPE screens till the RECIPE: Turret
and Outfeed screen is displayed.

Fig. 5-38 RECIPE: Turret and Outfeed screen

The values in the Recipe Value column are the parameter values stored in
selected recipe and the values under Current Value are the parameter values
currently active in the machine. For an explanation of the parameters of the
RECIPE: Turret and Outfeed screen, see the section PRODUCTION: Turret
and Outfeed screen.

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Recipe screens

5.13.4 RECIPE: Brushing screens

To go to the RECIPE: Brushing 1 / Brushing 2 screen:

▪ Tap the Brushing 1 / Brushing 2 icon on the machine graphic of the

RECIPE: Home screen OR
▪ Tap the scroll keys on any of the RECIPE screens till the RECIPE:
Brushing 1 / Brushing 2 screen is displayed.

Fig. 5-39 RECIPE: Brushing 1 screen

Fig. 5-40 RECIPE: Brushing 2 screen

The values in the Recipe Value column are the parameter values stored in
selected recipe and the values under Current Value are the parameter values
currently active in the machine. For an explanation of the parameters of the
RECIPE: Brushing 1 / Brushing 2 screen, see the section PRODUCTION:
Brushing 1 / Brushing 2 screen.

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Recipe screens

5.13.5 RECIPE: Cutting screen

To go to the RECIPE: Cutting screen:

▪ Tap the Cutting icon on the machine graphic of the RECIPE: Home screen
OR
▪ Tap the scroll keys on any of the RECIPE screens till the RECIPE: Cutting
screen is displayed.

Fig. 5-41 RECIPE: Cutting screen

The values in the Recipe Value column are the parameter values stored in
selected recipe and the values under Current Value are the parameter values
currently active in the machine. For an explanation of the parameters of the
RECIPE: Cutting screen, see the section PRODUCTION: Cutting screen.

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Alarm screens

5.14 Alarm screens

5.14.1 ALARM: Current Alarm screen
To go to the ALARM: Current Alarm screen:

▪ Tap the Alarm Navigation key on any screen

▪ Tap the error message displayed at the top of any screen
▪ Tap the Current Alarm key on the ALARM: Historical Alarm screen

Fig. 5-42 ALARM: Current Alarm screen

The elements of the ALARM: Current Alarm screen are explained below:

The ALARM: Current Alarm screen is the maximized view of the alarm and
event messages already displayed on any screen. The screen lists the alarm
class, alarm number, time and date of occurrence and the alarm / event
message.

-Help:
Selecting any alarm message and then tapping this key will display the
recommended remedial action in a pop-up window titled Info text. Tapping the
X icon on the title bar will close the Info text window.
User level/ Mode: 1, 2, 3 / S, M, A

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5 - Operation
Alarm screens

5.14.2 ALARM: Historical Alarm screen

Tap the Historical Alarm key on the ALARM: Current Alarm to go to the
ALARM: Historical Alarm screen.

Fig. 5-43 ALARM: Historical Alarm screen

The ALARM: Historical Alarm screen displays the older messages stored
in the message buffer. Depending on the flash memory capacity, the buffer
stores messages on a FIFO (First-in-first-out) basis, meaning earliest
messages will be deleted to accommodate newer ones.

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Settings screens

5.15 Settings screens

5.15.1 SETTINGS: Home screen
To go to the SETTINGS: Home screen:

▪ Tap the Settings Navigation key on any screen

Fig. 5-44 SETTINGS: Home screen - For representation only

The elements of the SETTINGS: Home screen are explained below:

Set Date & Time:

Resets the system date and time.

CALIBRATE screen:
Starts the screen calibration process that serves to correctly align the touch
panel coordinates with the display.
User level: 3

EXIT runtime:
Exits the User interface screen to the Windows control panel.
User level: 3

EXPORT Alarm to USB (Option):

Exports the historical alarm lists from the operating panel to the USB device.
Plug in the USB device to the USB port and tap this key. A pop-up window with
the message “Log files copied successfully” appears on the screen after the
data transfer is complete. The alarm lists are exported in CSV (Comma
delimited) format.
User level: 3

IMPORT/EXPORT Recipe to USB (Option):

Imports or exports the recipe data between the operating panel and the USB
device.
User level: 3

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5 - Operation
Settings screens

Machine graphic
The icons of the machine graphic on the SETTINGS: Home screen serve as
shortcuts to the SETTINGS screens of the corresponding machine modules.
They also indicate the status (ON or OFF) of the different modules.

Refer to the section “Machine graphic” in this chapter for

information about the different icons on the machine graphic.

Tap the required icon on the machine graphic to go to the SETTINGS screen
of the corresponding machine module.

Fig. 5-45 SETTINGS screen - For representation only

The differentSETTINGS screens display the status of the various machine

hardware modules.

It is possible to disable certain modules that are either dysfunctional or needed

to be removed for maintenance or repairs, and still operate the machine. The
modules can be enabled or disabled by selecting the ACTIVE or INACTIVE
option respectively against each hardware module.

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Information screens

5.16 Information screens

5.16.1 INFORMATION: Production Counter screen
To go to the INFORMATION: Production Counter screen:

▪ Tap the Information navigation key on any screen.

11

12
1
2
3
5 6
4
7

8 9
10
Fig. 5-46 INFORMATION: Production Counter screen - for representation only

The elements of the INFORMATION: Production Counter screen are as

follows:

Weekly production window (1):

Displays the production details for the different days of the week. Tap on any
day to see the day’s detailed production details in the Daily production window
(4).

Good product counter (2):

Displays the total number of good products produced on the selected day.

Production time (3):

Displays total time for which the machine was in actual production on the
selected day.

Daily production window (4):

Displays the day-wise, hour-wise and shift-wise production details for the
selected day.

Daily production counters (5):

Displays the total number of production processed, total number of good
products processed and the total number of products rejected on the selected
day.

Shift production details (6):

Displays the total number of good products processed in the different shifts
of the selected day. It also displays the machine uptime (Green triangle) and
machine downtime (Red inverted triangle) in the different shifts.

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5 - Operation
Information screens

Hour-wise production details (7):

Graphically displays the total good products produced in the current hour.
When you tap this tab, a pop-up window displays the production details (total
production, total good products produced and total products rejected) for the
selected hour.

Fig. 5-47 Hour-wise production details

Shift settings (8)

Displays the shift settings window for defining the number and duration of the
production shifts.

Fig. 5-48 Shift settings

Shift 1, Shift 2, Shift 3: Defines the start timings of the respective shifts.

Adds a new production shift. A maximum of 4 shifts can be

defined.

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Information screens

Deletes a production shift.

Current (9)
Displays the INFORMATION: Production Counter screen for the current
week.

Previous (10)
Displays the INFORMATION: Production Counter screen for the previous
week.

Power monitoring (11)

Displays the INFORMATION: Power monitoring screen.

Production counter (12)

Displays the INFORMATION: Production Counter screen.

5.16.2 INFORMATION: Power monitoring screen

To go to the INFORMATION: Power monitoring screen:

▪ Tap the Power monitoring key on the INFORMATION: Production

Counter screen.

1 11
2

3
5 6
4
7

8 9
10
Fig. 5-49 INFORMATION: Power monitoring screen - for representation only

The elements of the INFORMATION: Power monitoring screen are as

follows:

Weekly power consumption(1):

Displays the power consumption details for the different days of the week. Tap
on any day to see the day’s detailed power consumption details in the Daily
power consumption window (4).

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5 - Operation
Information screens

Total active energy (2):

Displays the total power consumption of the machine since its commissioning.
This value can be reset at the power monitoring panel on the main electrical
cabinet.

Total daily power consumption (3):

Displays the total power consumed on the selected day.

Daily power consumption window (4):

Displays the day-wise, hour-wise and shift-wise power consumption details
for the selected day.

Active power (5):

Displays the actual active power in real time.

Voltage and current values (6):

Displays the actual voltage and current values in real time. The following
information is displayed.

Voltages L-N (V)

L1-N: Displays the voltage between line 1 and neutral.
L2-N: Displays the voltage between line 2 and neutral.
L3-N: Displays the voltage between line 3 and neutral.

Voltages L-L (V)

L1-L2: Displays the voltage between line 1 and line 2.
L2-L3: Displays the voltage between line 2 and line 3.
L3-L1: Displays the voltage between line 3 and line 1.

Current (A)
L1: Displays the current in line 1.
L2: Displays the current in line 2.
L3: Displays the current in line 3.

Hour-wise power consumption details (7):

Graphically displays the total power consumed in the current hour.

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Information screens

Power Monitoring trend GRAPH (8):

Displays the power monitoring trend window which shows the plots of the
actual voltage [V] and the actual current [A] relative to time.

Fig. 5-50 Power monitoring trend graph (for representation only)

The y-axis to the left represents the voltage scale. The y-axis to the right
represents the current scale. The x-axis shows the present time originating
from the left. The red line indicates the actual current and the green line
indicates the actual voltage at any given point of time.

The default display shows the plots of actual current and

voltage over a time span of the last one hour. But the view can
be zoomed out to display a time span of the last several hours.

Also, the ruler in the middle of the graph can be shifted

to the left or to the right to intersect the plots and the
ordinate values can be read in the lower window.

Current (9)
Displays the INFORMATION: Power monitoring screen for the current week.

Previous (10)
Displays the INFORMATION: Power monitoring screen for the previous
week.

Production counter (11)

Displays the INFORMATION: Production counter screen.

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5 - Operation
Operating modes

5.17 Operating modes

The machine can be operated in three modes: Setup, Auto and Inching. This
section explains how to start and stop the machine and restart the machine
after an interruption.

5.17.1 Machine startup

Prerequisites ▪ Check the availability of inputs.
– Mains electrical power
– Compressed air
– Printing inks, lacquer, solvents, etc., if applicable
– Coolant water, if applicable
– Gas fuel, if applicable
– Raw material

▪ Check if the upstream and downstream machines are ready.

▪ Close all doors of the machine.
▪ Release all [Emergency stop] buttons, if activated.
▪ Turn ON the compressed air supply to the machine.
– Check if a minimum air pressure of 6 bar is available.

Start-up 1. Turn ON the mains power switch on the electrical cabinet of the machine.
▪ The Welcome screen appears on the touchscreen after initialization
of the operating software.

2. Tap anywhere on the Welcome screen.

▪ The PRODUCTION: Home screen appears on the touchscreen.

3. Login with the authorised user level.

▪ The default user (Operator) require a password (1111) to login.
▪ For other users, separate passwords are required to login.

4. Manually solve all the errors in the machine.

5. Press the [Reset] push button on the control panel to clear all errors when
the errors are no longer valid.
▪ The [Start] push button may blink fast to indicate that the machine
needs to reference to its home position.

6. Press the [Start] push button on the control panel.

▪ The machine drives start to reference to their home positions and in
the meantime, the hooter raises an alarm for nearly three seconds. When
the referencing procedure is successful, the [Start] push button will blink
to show that the machine is ready to start.

■ End of the procedure.

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Operating modes

5.17.2 Setup mode

Purpose The Setup mode is used to check the single movements of an individual
machine module. When the machine stops or the module is deactivate (OFF)
it is possible to access setup function by pressing each setup button manually
for setups and troubleshooting of the particular machine module.

Prerequisites ▪ Check the availability of inputs, such as power and compressed air.
▪ Release all [Emergency stop] buttons, if activated.
▪ Close all doors of the machine, except when the [Manual comply] switch
is activated.

Setup mode 1. Manually solve all the errors in the machine.

2. Press the [Reset] push button on the control panel to clear all errors when
the errors are no longer valid.

3. Go to the module screen of the machine module that needs to be set up.
Edit the setup speed and other parameters of the particular module, if
required.

4. Tap and hold the respective [Function JOG] key to jog the particular module
drive/function and check the single movement/function of the module. Edit
the parameters to fine-adjust the function/movement.

5. Go to other module screens and repeat steps 3 and 4 to set up/fine-adjust

the other machine modules/functions.

■ End of the procedure.

5.17.3 Inching mode

Purpose The Manual or Inching mode is used to inch the whole machine when all the
machine modules are individually set up and synchronized with each other.
This mode is used to check if all functions and product transfers are smooth
and error-free before putting the machine into Auto mode.

Prerequisites ▪ Check the availability of inputs, such as power and compressed air.
▪ Release all [Emergency stop] buttons, if activated.
▪ Close all doors of the machine, except when the Manual comply function
is activated.

Manual Mode 1. Manually solve all the errors in the machine.

2. Press the [Reset] push button on the control panel to clear all errors when
the errors are no longer valid.

3. On the PRODUCTION: Home screen, tap the [Inching mode ACTIVE] key
to activate the Inching mode of the machine.

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Operating modes

4. Set the desired inching speed in the [Inching Speed] parameter on the
PRODUCTION: Home screen.

5. Go to the different module screens and enable/ disable the required

modules.

6. Press the [Start] push button on the control panel.

▪ The machine drives start to reference to their home positions and in
the meantime, the hooter raises an alarm for nearly three seconds. When
the referencing procedure is successful, the [Start] push button will blink
to show that the machine is ready to start.

7. Press and hold the [Start] push button to inch the machine. The machine
stops when the [Start] button is released.

When you release the Start button, the machine stops and the
hooter gives an audio signal for 9 seconds to indicate that the
Inching mode is still active.
After 9 seconds, the inching mode is deactivated.

■ End of the procedure.

5.17.4 Auto mode

Purpose This is the normal mode of machine operation. The machine can be operated
in this mode after the machine is set up for production in Setup and Manual
modes.

Prerequisites ▪ Check the availability of inputs, such as power and compressed air.
▪ Release all [Emergency stop] buttons, if activated.
▪ Close all doors of the machine.

Auto Mode 1. Manually solve all the errors in the machine.

2. Press the [Reset] push button on the control panel to clear all errors when
the errors are no longer valid.

3. Go to the RECIPE: Home screen and load a recipe. Edit the loaded recipe,
if needed.

4. Press the [Start] push button on the control panel.

▪ The machine drives start to reference to their home positions and in
the meantime, the hooter raises an alarm for nearly three seconds. When
the referencing procedure is successful, the [Start] push button will blink
to show that the machine is ready to start.

5. Press the [Start] button once again to start the machine.

The machine will start to run after the 3-second pre-start warning
alert has elapsed.

■ End of the procedure.

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Operating modes

5.17.5 Interrupting the machine operation

1. Press the [Stop] push button to stop the machine.
▪ The machine goes to a controlled safe stop at its next home position.

5.17.6 Restarting the machine after an interruption

1. Press the [Reset] push button to acknowledge the alarm and mute the
hooter.

2. Manually solve all the errors in the machine.

3. Press the [Reset] push button on the control panel to clear all errors when
the errors are no longer valid.

4. Press the [Start] push button on the control panel.

▪ The machine drives start to reference to their home positions and in
the meantime, the hooter raises an alarm for nearly three seconds. When
the referencing procedure is successful, the [Start] push button will blink
to show that the machine is ready to start.

5. Press the [Start] button once again to start the machine.

The machine will start to run after the 3-second pre-start warning
alert has elapsed.

■ End of the procedure.

5.17.7 Stopping the machine in case of an emergency

1. Press the nearest [Emergency stop] button.
▪ Activating the emergency stop results in instantaneous disconnection
of electrical power and immediate mechanical stoppage of the machine
and its connected peripheral equipment.

■ End of the procedure.

5.17.8 Restarting the machine after an emergency stop

Prerequisites ▪ Find out why the Emergency stop had to be activated, and ensure that
restarting the machine will not put any one at risk again.
▪ Remove all the trapped/semi-processed products from the machine.
▪ Release the [Emergency stop] buttons.

Restarting the machine To restart the machine:

1. Manually solve all the errors in the machine.

2. Press the [Reset] push button on the control panel to clear all errors when
the errors are no longer valid.

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5 - Operation
Operating modes

3. Press the [Start] push button on the control panel.

▪ The machine drives start to reference to their home positions and in
the meantime, the hooter raises an alarm for nearly three seconds. When
the referencing procedure is successful, the [Start] push button will blink
to show that the machine is ready to start.

4. Press the [Start] button once again to start the machine.

The machine will start to run after the 3-second pre-start warning
alert has elapsed.

■ End of the procedure.

5.17.9 Shutting down the machine

1. Empty the machine of all products.

2. Open the safety door and clean the various units of the machine.

3. Press and hold the [Stop] push button for 3 seconds.

4. Turn OFF the mains power switch.

5. Close the compressed air supply.

■ End of the procedure.

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5 - Operation
Managing recipes

5.18 Managing recipes

5.18.1 Creating a new recipe
1. Tap the [Recipe] navigation key on any screen to go to the RECIPE: Home
screen.

2. Tap the [NEW recipe] key.

▪ A pop-up window (1) for entering the name, description of the recipe
appears.

1
2

4 5

6
7

Fig. 5-51 Pop-up window

3. Tap the Recipe name (2) field.

An on-screen keyboard appears.

4. Type the desired name of the recipe and tap the Enter key on the on-screen
keyboard.

5. Tap the Description (3) field.

An on-screen keyboard appears.

6. Type the desired description of the recipe and tap the Enter key on the on-
screen keyboard.

7. Set the Diameter (4), and Length (5) at the respective fields.

8. The Author (6), Created data and time (7), and Last edited data and time
(8) will be displayed at these fields.

9. Tap the Confirm key (9) on the pop-up window (1) to confirm the set details
of the recipe.
▪ A new recipe consisting of parameter values currently active on the
machine is created.

■ End of the procedure.

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5 - Operation
Managing recipes

5.18.2 Loading a recipe to the machine

1. Tap the [Recipe] navigation key on any screen to go to the RECIPE: Home
screen.

2. Select the required recipe from the list of recipes.

3. Tap the [LOAD recipe] key.

▪ A pop-up window with the message “Do you want to load the recipe
values to machine?” appears on the screen.

Fig. 5-52 Pop-up window

4. Tap the confirm key on the pop-up window to load the recipe to the machine.

All parameter values currently active on the machine will now be

replaced by the corresponding values in the recipe.

■ End of the procedure.

5.18.3 Editing a recipe

1. Edit the parameters in all the PRODUCTION screens according to the
product / process requirements.

2. Run the machine in the MANUAL and AUTO modes to check the process
quality and stability under the new parameter values.

3. Adjust the values of the parameters again in the PRODUCTION screens,

if necessary.

4. Tap the [Recipe] navigation key on any screen to go to the RECIPE: Home
screen.

5. Select the recipe to be edited from the list of recipes.

6. Tap the [EDIT recipe] key to open the selected recipe for editing.

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5 - Operation
Managing recipes

7. Go to the different RECIPE screens. The parameter values in the selected

recipe are listed under the column “Recipe Value” (5). The actual
parameter values active on the machine are listed under the column
“Current Value” (6).

5 6
Fig. 5-53 Recipe screen (for representation only)

8. Tap the [COPY Current to Recipe] key to upload the values currently active
on the machine to the selected recipe.
▪ A pop-up window with the message “Are you sure you want to overwrite
the recipe values with the current values? or create a new recipe from the
current values?”

Fig. 5-54 Pop-up window

9. Tap the [COPY Current to Recipe] key to upload the values currently active
on the machine to the selected recipe.

10. OR Tap the [NEW recipe] key to create a new recipe from the current
values.
▪ A pop-up window (1) for entering the name and description of the
recipe appears on the screen. Refer to the section “Creating a new recipe”
for the detailed procedure.

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5 - Operation
Managing recipes

11. Tap the [SAVE recipe] key to save the edited recipe.
▪ A pop-up window with the message “Do you want to save the open
recipe” appears on the screen.

Fig. 5-55 Pop-up window

12. Tap the Confirm key on the pop-up window to save the recipe.

13. Tap the [Recipe] navigation key on any screen to go to the RECIPE: Home
screen.

14. Select the edited recipe from the list of recipes.

15. On the Recipe: Home screen Tap the [LOAD recipe] key.
▪ A pop-up window with the message “Do you want to load the recipe
values to machine?” appears on the screen.

Fig. 5-56 Pop-up window

16. Tap the confirm key on the pop-up window to load the recipe to the machine.

All parameter values currently active on the machine will now be

replaced by the corresponding values in the recipe.

■ End of the procedure.

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5 - Operation
Managing recipes

5.18.4 Deleting a recipe

1. Tap the [Recipe] navigation key on any screen to go to the RECIPE: Home
screen.

2. Select the recipe to be edited from the list of recipes.

3. Tap the [DELETE recipe] key.

▪ A pop-window with the message “Do you want to delete the selected
recipe?” appears on the screen.

Fig. 5-57 Pop-up window

4. Tap the confirm key on the pop-up window to delete the recipe.

■ End of the procedure.

Operating Manual V1.0 Zelos 5-67

5 - Operation
Operating the Can cutting and brushing line

5.19 Operating the Can cutting and brushing line

The Zelos machine has to be run together in synchronization with the Impact
extrusion press, the Washer (PCW) and Accumulator (Accu-Washer). The
individual machines have to be set up for production before they are run
together in synchronization.

5.19.1 Setting the Zelos machine up for production

Refer to chapter 6 for setting up, adjustment and replacement of tools and
devices at the different working stations:

▪ Wall length cutting unit

▪ Wall brushing and stripper units

5.19.2 Prerequisites for starting the line

▪ The Zelos machine is mechanically set up for the cutting and brushing
functions for the relevant recipe to be loaded on the machine.
▪ The Extrusion press is ready to be synchronized with the Zelos machine.
▪ The utilities, such as electric power and compressed air to the Zelos
machine are turned on. The air pressure is at least 6 bar.
▪ All the faults displayed on the touchscreen are cleared and reset.

5.19.3 Starting the Washing machine

1. Eliminate the faults, if any, displayed on the touchscreen of the Zelos
machine, and push the Reset button on the operating panel of the
machine.

2. On the PRODUCTION: Oven screen, tap the Line mode key to activate
the Washer line mode. The Washer chain drive is synchronized with the
Zelos machine.

3. Activate the Start push button on the operating panel to reference the
Washer chain drive.

4. After referencing is complete, press the Start push button on any operating
panel once again. After the hooter sounds a pre-start warning alert, the
Washer chain will start to run in the Auto mode.

5. On the PRODUCTION: Oven screen, tap the Burner On/Off key to switch
ON the burner of the Washer oven.

The exhaust and circulation fans will be switched ON automatically.

The burners will start only after the purging process of oven is
complete.

6. Allow the oven chain loops to run empty, and the oven chamber to reach
the setpoint production temperature before starting the Zelos and Impact
extrusion press machines.

■ End of the procedure.

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5 - Operation
Operating the Can cutting and brushing line

5.19.4 Starting the line in ‘Auto’ mode

1. On the PRODUCTION: Brushing screen, tap the Brush On/Off key to
activate the brushing units 1 or 2 or both.

2. On the PRODUCTION: Cutting screen, tap the Cutting On/Off key to

activate the cutting unit.

3. On the PRODUCTION: Recipe screen, load the required recipe.

4. Edit and save the parameters, if required.

5. Ensure all doors are closed.

6. Press the Reset push button after manually removing all the faults.

7. Press the Start push button on the operating panel of the Zelos machine.
After the hooter sounds a series of short beeps followed by a long beep,
push the button once again to start the machine.

■ End of the procedure

5.19.5 Interrupting production

1. Press the Stop push button. The Zelos turret and the impact extrusion
press machine will stop at the next home position.

2. Press and hold the Stop push button for longer than 2 seconds to stop
the Washer chain.

3. The line stops automatically in case of warning and error messages

depending on the level of fault. The line stops at the next home position
for cycle stops and stops immediately in case of emergency stops.

■ End of the procedure.

5.19.6 Resuming production

When the line stops by a fault, the user can restart the line as follows:

1. Check the cause of the fault and remove the cause / disturbance.

2. Rectify all faults in the line and press the Reset push button.

3. Tap the Start push button to start the line again.

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5 - Operation
Operating the Can cutting and brushing line

5.19.7 Shutting down the Washer

If the washer needs to be shut down, the oven burner must be switched OFF
first. Following is the procedure for shutting down the Washer:

1. On the PRODUCTION: Oven screen, deselect the Burner On/Off key to

switch OFF the burner of the Washer oven.

2. Tap the Exhaust fan ON/OFF key (only in setup mode) to evacuate the
hot air from the oven. In the Auto mode the exhaust is automatically
switched ON to evacuate the hot air from the oven.

3. Allow the exhaust fan and the oven chain to keep running and the manually-
operated exhaust valve to remain open until the oven work space
temperature has dropped substantially below 100°C.

4. Switch OFF the circulation and exhaust fans.

5. Switch OFF the oven chain drive motors.

■ End of the procedure.

5.19.8 Shutting down the Zelos machine

1. Press and hold the Stop push button for 3 seconds.

2. Turn OFF the Mains power switch at the main electrical cabinet.

3. Close the air supply to the machine / line.

■ End of the procedure.

5.19.9 Operating the Zelos machine in Inching mode

The machine can be started in Inching mode before production or to check
their functioning and proper transfer of products with the other parts of the line.

To operate the machine in the Inching mode:

1. On the PRODUCTION: Home screen, tap the Inching mode ACTIVE key.

2. Press and hold the Start push button on the operating panel, or press the
Inching button on the hand-held unit to inch the machine in inching mode.
The machine stops when the Inching button / Start push button is released.

■ End of the procedure.

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5 - Operation
Operating the Can cutting and brushing line

5.19.10 Operating the Zelos machine in Setup mode

In the Setup mode, the single movement of each machine module is checked
independently of other modules. To run an individual machine module of the
machine in the Setup mode:

1. Go to the PRODUCTION screen of the selected module and edit the

machine parameters, if required.

2. Tap and hold the particular JOG key or just tap the ON/OFF function key
to inch / check the single movements/function of the module. The
movement/function stops when the key is released.

3. Repeat steps 2 and 3 to set up and check the functionality of the other
machine modules.

■ End of the procedure.

Operating Manual V1.0 Zelos 5-71

5 - Operation
Operating the Can cutting and brushing line

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5-72 Zelos Operating Manual V1.0

6 - Size part changeover and settings
About size parts changeover

6 Size part changeover and settings

6.1 About size parts changeover

This chapter provides information about size part changeover procedures and
the required tools. A change of size parts is required, when there is a product
size changeover.

Use only original PackSys Global supplied size parts and spare
parts. Use of third-party-supplied parts voids the guarantee in case
of any damage.

6.1.1 Tools required

A set of Allen keys, feeler gauges and wrenches are required.

6.1.2 Prerequisites
Before starting with a changeover procedure, ensure that:

▪ All size parts for the changeover are checked for completeness and
defects.
▪ The machine is ready for operation.

Operating Manual V1.0 Zelos 6-1

6 - Size part changeover and settings
Necessity for size part change and settings

6.2 Necessity for size part change and settings

Resetting and dismantling operations on the Zelos must be done when:

▪ there is a change in product size.

▪ there is maintenance work on the machine.

Part to be changed/adjusted Change in Change in

product diameter product length
Guide plate - Press transfer - Adjust
conveyor infeed
Guide plate - Press transfer - Adjust
conveyor outfeed
Roll sheet - press transfer Change* -
conveyor outfeed
Intermediate drum Change* -
Roll sheet - intermediate drum Change* -
Feeding drum Change* -
Mandrels Change -
Feeding pushers - Adjust
Wall length cutting unit Adjust Adjust
Pressure roller unit Change* -
Brushing unit Adjust Adjust
Product gripper Change* -
Sensors Adjust Adjust
Chain peg guide wheel - Adjust
Brush roll Adjust Change*
Stripper plates Change -
* These parts can be the same for a range of product diameters/lengths.

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6 - Size part changeover and settings
Changing the mandrels

6.3 Changing the mandrels

The mandrels are size-specific parts and must be changed for every change
in the diameter of the product. The mandrels are changed at Station 16 of the
turret. A pneumatic ejector is provided at Station 16 of the turret behind the
mandrels to eject the mandrels out of their self-locked position.The procedure
for changing the mandrels is as follows:

Prerequisites ▪ The machine is stopped.

▪ The front safety door of the machine is open.
▪ The brushing unit, cutting unit, and de-burring unit are at their outermost
positions (Refer to the respective sections in this chapter for the detailed
procedures).
▪ The product position sensor on the turret is at its outermost position.
▪ The scrap suction channel is swivelled to its uppermost position.
▪ The feeding drum, pressure rollers, and stripper plates are removed.
▪ The mandrels for the required product size are available.

Tools required No tools are required.

1. Turn the mandrel ejector air valve (1) to open the compressed air supply
to the ejector cylinder. The mandrel ejector air valve is located on the
pneumatic panel beside the front safety door. Maintain a pressure of 3-
4 bar.

Fig. 6-1 Mandrel ejector air valve

2. On the PRODUCTION: Turret and Outfeed screen, tap the More key next
to the Turret JOG FORWARD key.

Operating Manual V1.0 Zelos 6-3

6 - Size part changeover and settings
Changing the mandrels

3. In the pop-up window that appears, tap the Mandrel change ON/OFF key
to activate the mandrel change function.

Fig. 6-2 Pop-up window

4. Hold the mandrel (2) and press the [Mandrel eject] button (3). The mandrel
is ejected. Press the button repeatedly till the mandrel comes out.

Fig. 6-3 Removing the mandrel

5. Insert the mandrel of the required size into the mandrel sleeve and turn
slightly till the ball plungers snap into the groove of the mandrel shaft. The
mandrel is now locked into the mandrel drive pulley.

Refer to the section ‘Protecting the mandrels’ of this chapter before

inserting the new mandrels into the mandrel sleeves.

6. On the PRODUCTION: Turret and Outfeed screen, tap the More key next
to the Turret JOG FORWARD key.

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6 - Size part changeover and settings
Changing the mandrels

7. In the pop-up window that appears, tap the Turret INDEX CYCLE key. The
turret indexes and stops automatically after one indexing.

Fig. 6-4 Pop-up window

8. Repeat the steps 4-7 until all mandrels are changed.

9. On the PRODUCTION: Turret and Outfeed screen, tap the More key next
to the Turret JOG FORWARD key.

10. In the pop-up window that appears, tap the Mandrel change ON/OFF key
to deactivate the mandrel change function.

Fig. 6-5 Pop-up window

11. Set the mandrel ejector air regulator valve (1) to zero.

■ End of the procedure.

Operating Manual V1.0 Zelos 6-5

6 - Size part changeover and settings
Protecting the mandrels

6.4 Protecting the mandrels

The mandrel bearing sleeves and the mating surfaces of the mandrels have
to be coated with a film of heat-resistant lubricating grease before installing
the mandrels during a mandrel changeover.

The removed mandrels have to be well-protected against dust and moisture

during their storage.

Prerequisites ▪ The machine is stopped.

▪ All mandrels are removed from the turret. Refer to the previous section,
“Changing the mandrels”.

Tools and lubricants ▪ A paint brush.

required ▪ Some lint-free cloth.

▪ OKS 250 Paste or an equivalent solid lubricating paste.

▪ WD-40 Smart Straw or an equivalent rust-removing spray.
▪ Rustkote 943 or an equivalent rust preventive fluid.

1. Clean the inside of the mandrel bearing sleeve (1) of any residual rust with
WD-40 spray and cloth at the mandrel ejection station (or any empty station
after all the mandrels are ejected) of the turret.

Fig. 6-6 Cleaning and lubricating the mandrel bearing sleeve

2. Apply a coat of grease (OKS 250 Paste) on the inside of the mandrel
bearing sleeve with a paint brush.

3. Clean the new mandrel with WD-40 spray and a piece of cloth.

4. Apply a film of grease (OKS 250 Paste) with a paint brush on the part of
the mandrel (2) that will be seated in the mandrel bearing sleeve.

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6 - Size part changeover and settings
Protecting the mandrels

Fig. 6-7 Applying grease on the mating surface of the mandrel

5. Insert the new mandrel into the mandrel sleeve at the mandrel ejection
station.

6. Repeat steps 1 through 5 until all mandrels are changed.

Perform this preventive maintenance task every two weeks for all
mandrels and mandrel bearing sleeves even if the mandrels are
not changed.

Storing the removed 7. Clean the removed mandrels of residual rust and dirt with WD-40 and a
mandrels cleaning cloth.

8. Apply a coat of rust-preventive fluid such as Rustkote 943 on the surface

of the mandrels (3) for long-term rust protection.

Fig. 6-8 Applying rust-preventive fluid on the mandrel

9. Store the mandrels in a dust and moisture-free environment.

■ End of the procedure.

Operating Manual V1.0 Zelos 6-7

6 - Size part changeover and settings
Feeding drum

6.5 Feeding drum

6.5.1 Changing the feeding drum
When the product diameter changes, the feeding drum must be changed.

Prerequisites The front safety door of the machine is open.

Tools required No tools are required.

1. Turn the clamping lever (1) counter-clockwise.

Fig. 6-9 Feeding drum

2. Loosen the knob (2).

3. Pull the feeding drum (3) out.

4. Mount the feeding drum (3) for the required product size.

Make sure that the locating pin (4) on the drum shaft is seated in
the hole (5) on the feeding drum.

5
3

Fig. 6-10 Installing the feeding drum

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6 - Size part changeover and settings
Feeding drum

5. Tighten the knob (2).

6. Turn the clamping lever (1) clockwise.

■ End of the procedure.

6.5.2 Aligning the feeding drum pocket against the mandrel

If the feeding drum pocket is not in radial alignment with the mandrel, the
product may get jammed during feeding. This can be adjusted as below.

Prerequisites The front safety door of the machine is open.

Tools required No tools are required.

1. On the PRODUCTION: Turret and Outfeed screen, tap the More key next
to the Feeding drum CYCLE key.

2. In the pop-up window that appears, tap and hold the Feeding drum
REFERENCE key. The feeding drum drive is referenced. The feeding
drum stops at its reference position.

Fig. 6-11 Pop-up window

3. Enter the required value in the Offset parameter field. The feeding drum
moves to the new position.

4. Slide a product between the feeding drum pocket and the mandrel.

5. If the product does not move smoothly from the feeding drum pocket to
the mandrel, change the Offset value and check the alignment again.
Repeat this process until the transfer is smooth.

■ End of the procedure.

Operating Manual V1.0 Zelos 6-9

6 - Size part changeover and settings
Feeding drum

6.5.3 Adjusting the gap between the feeding drum and the mandrel
The feeding drum can be moved towards or away from the mandrel for the
smooth transfer of products from the feeding drum to the mandrel.

This adjustment is not necessary during a size part change. The

gap between the feeding drum axis and the mandrel is pre-set at
the factory and is required only when the setting is disturbed.

Prerequisites The front safety door of the machine is open.

Tools required A set of spanners.

1. Loosen the four hex screws (1).

Fig. 6-12 Feeding drum adjustment

2. Turn the spindle (2) clockwise or counter-clockwise to move the feeding

drum (3) away or towards the mandrel respectively.

3. Tighten the four hexagonal head screws (1) after the desired position is
reached.

■ End of the procedure.

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6 - Size part changeover and settings
Intermediate drum

6.6 Intermediate drum

6.6.1 Changing the intermediate drum
When the product diameter changes, the intermediate drum must be changed.

Prerequisites The front safety door of the machine is open.

Tools required No tools are required.

1. Pull out, and then turn the clamping lever (1) by 180° to hold it in its unlocked
position.

3
1

Fig. 6-13 Removing the intermediate drum

2. Pull out the intermediate drum (2) from the shaft (3).

3. Pull out, and then turn the clamping lever (1) on the new intermediate drum
by 180° to hold it in its unlocked position.

4. Slide the new intermediate drum (2) onto the shaft (3).

Make sure that the key (4) on the drum shaft is seated in the slot
(5) on the intermediate drum.

2 43

Fig. 6-14 Mounting the intermediate drum

Operating Manual V1.0 Zelos 6-11

6 - Size part changeover and settings
Intermediate drum

5. Turn and then release the clamping lever (1). The clamping lever snaps
into the hole on the intermediate drum shaft.

■ End of the procedure.

6.6.2 Changing the roll sheet below the intermediate drum

The roll sheet (1) below the intermediate drum guides the products from the
intermediate drum to the feeding drum. When you change to a different product
diameter, the roll sheet must be changed. The procedure for changing the roll
sheet is as follows:

Prerequisite ▪ The front safety door of the machine is open.

▪ The intermediate drum for the required product size is mounted.

Tools required No tools are required.

1. Pull the roll sheet (1) out from the mounting block (2).

Fig. 6-15 Removing the roll sheet

2. Slide the roll sheet for the required product size into the mounting block
(2) till the four ball plungers (3) snap into the slots (4) on the roll sheet guide
plate (5).

3 2

5 4

Fig. 6-16 Mounting the roll sheet

■ End of the procedure.

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6 - Size part changeover and settings
Intermediate drum

6.6.3 Adjusting the intermediate drum against the feeding drum

The position of the intermediate drum pocket must be adjusted relative to the
feeding drum pocket, for a smooth transfer of products. This can be adjusted
as follows:

Prerequisites ▪ The front safety door of the machine is open.

▪ The feeding drum pocket is aligned to the mandrel (Refer to the section
“Aligning the feeding drum pocket against the mandrel” in this chapter for
the detailed procedure).

Tools required No tools are required.

1. On the PRODUCTION: Turret and Outfeed screen, tap the More key next
to the Press transfer conveyor JOGkey.

2. In the pop-up window that appears, tap and hold the Infeed REFERENCE
key. The infeed drive is referenced. The intermediate drum stops at its
reference position. The intermediate drum is driven by the infeed drive.

Fig. 6-17 Pop-up window

3. Enter the required value in the Offset parameter field. The intermediate
drum moves to the new position.

4. Inch the machine and check for smooth transfer of products from the
intermediate drum to the feeding drum.

5. Change theOffset value to fine-adjust the transfer of products, if

necessary.

■ End of the procedure.

Operating Manual V1.0 Zelos 6-13

6 - Size part changeover and settings
Intermediate drum

6.6.4 Adjusting the intermediate drum against the roll sheet

The radial position of the intermediate drum can be adjusted for a smooth
transfer of products from the roll sheet to the feeding drum.

This is not necessary during a size part change. This is preset at

the factory and is required only when the setting is disturbed.

Prerequisites ▪ The front safety door of the machine is open.

▪ Sample (unfinished) cans are available.

Tools required A set of Allen keys.

1. Loosen the four Allen screws (1).

Fig. 6-18 Radial adjustment of the intermediate drum

2. Turn the intermediate drum (2) clockwise or counter-clockwise as required

till the transfer from the rollsheet to the feeding drum is smooth.

3. Tighten the four Allen screws (1).

■ End of the procedure.

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6 - Size part changeover and settings
Intermediate drum

6.6.5 Re-engaging the overload clutch after a jam

In case of an overload or jam, the overload clutch (2) of the intermediate drum
(1) disengages and trips the limit switch (3). The overload clutch must be re-
engaged as follows:

Prerequisites ▪ The front and side safety doors of the machine are open.

Tools required No tools are required.

1. Remove the jammed products on the intermediate drum.

2. Manually turn the intermediate drum (1) till the overload clutch (2) engages.
The limit switch (3) returns to its working position.

1
2

Fig. 6-19 Re-engaging the overload clutch

■ End of the procedure.

Operating Manual V1.0 Zelos 6-15

6 - Size part changeover and settings
Feeding pusher unit

6.7 Feeding pusher unit

6.7.1 Setting the first feeding pusher
The first feeding pusher (1) pushes the product by approximately half the
product length onto the mandrel. For different product lengths, the pusher can
be shifted on its base plate (2).

Prerequisites ▪ The front safety door of the machine is open.

▪ A product of the new length is available.

Tools required A set of Allen keys.

1. Inch the machine till the feeding pusher unit is at its outermost position.

2. Turn OFF the vacuum through the mandrels.

3. Place a product (3) on the mandrel at the first loading station.

4. Loosen the bolt (4).

2 4
1

Fig. 6-20 First feeding pusher

5. Inch the machine till the feeding pusher unit is at its innermost position.

6. Slide the product on the mandrel outwards by approximately half its length.

7. Move the feeding pusher towards the product such that the pusher just
touches the product. Use the product length marking on the side of the
base plate (2) as reference.

8. Tighten the bolt (4).

■ End of the procedure.

6-16 Zelos Operating Manual V1.0

6 - Size part changeover and settings
Feeding pusher unit

6.7.2 Resetting the feeding pusher unit after a crash

For safety, the feeding pusher unit is equipped with a safety mechanism. In
case of a jam, the feeding pushers retract from their working positions. This
causes a pressure drop in the pneumatic circuit. A sensor detects this sudden
drop in pressure and the machine goes to a fast stop. The feeding pusher unit
must be reset to their working positions to resume production.

Prerequisites The front safety door of the machine is open.

Tools required No tools are required.

1. Remove the jammed product from the mandrel.

2. Manually push the first (1) and second (2) feeding pushers to their
innermost positions until they snap to their positions.

Fig. 6-21 Resetting the feeding pushers

3. Press the Loading pusher reset button (3) located at the front of the turret.

Fig. 6-22 Resetting the feeding pushers

■ End of the procedure.

Operating Manual V1.0 Zelos 6-17

6 - Size part changeover and settings
Feeding pusher unit

The second feeding pusher has an additional safety mechanism (4) by which
the feeding pusher swings out of its position when it hits an improperly loaded
product on the mandrel. This is a self resetting mechanism.

Fig. 6-23 Self-resetting mechanism - Second feeding pusher

6-18 Zelos Operating Manual V1.0

6 - Size part changeover and settings
Wall length cutting station

6.8 Wall length cutting station

6.8.1 Replacing the knife revolver
When the knives on the current knife revolver get worn out, the knife revolver
can be replaced with a new knife revolver to quickly resume production. The
procedure is as follows:

Prerequisites ▪ The machine is stopped.

▪ The front and side safety doors are open.
▪ The new knife revolver (with good knives) is set in the adjusting jig (Refer
to the section “Setting the knife revolver in the adjusting jig” in this chapter
for the detailed procedure).

Tools required ▪ A set of spanners.

1. On the PRODUCTION: Cutting screen, tap the More key next the Knife
revolver INDEX MANUALkey. A pop-up window appears on the screen.

Fig. 6-24 Pop-up window

2. On the pop-up window, tap the Knife revolver lock RELEASE key. The
knife revolver lock is released.

3. Loosen and remove the locknut (1) by using a spanner. Hold the rear end
of the shaft (2) with another spanner.

3
Fig. 6-25 Replacing the knife revolver

4. Remove the knife revolver (3) from the shaft (2).

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6 - Size part changeover and settings
Wall length cutting station

5. Mount the new knife revolver onto the shaft (2). make sure that the key
(4) on the shaft is seated in the slot (5) on the knife revolver.

5 4
2

Fig. 6-26 Replacing the knife revolver

6. Insert and tighten the locknut (1). Hold the rear end of the shaft (2) with
another spanner while tightening the locknut.

■ End of the procedure.

6.8.2 Replacing the knife holder in the revolver

The knife holder can be removed from the knife revolver to change the knife
after the knife is worn out. After changing the knife, the knife holder can then
be installed in the knife revolver. The procedure is as follows:

Prerequisites ▪ The knife revolver is removed from the cutting station (Refer to the section
“Replacing the knife revolver” in this chapter for the detailed procedure).

Tools required ▪ A set of Allen keys.

1. Slightly loosen the Allen screw (1).

4
2

Fig. 6-27 Replacing the knife holder

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6 - Size part changeover and settings
Wall length cutting station

2. Turn the adjustment screw (2) counterclockwise until you can pull the knife
holder (3) out from the knife revolver (4).

3. Remove the knife holder from the knife revolver.

4. Insert the knife holder with the new knife into the knife revolver.

5. Turn the adjustment screw (2) clockwise to move the knife holder into the
knife holder.

The adjustment screw must turn very easily. If the adjustment screw
doesn’t turn easily, the knife holder is not inserted properly into the
knife revolver.

Do not tighten the Allen screw (1) as the knife distance to spacer
roller has not been set.

■ End of the procedure.

6.8.3 Replacing the knife in the knife holder

When the knife is worn out, the knife in the knife holder can be replaced as
follows:

Prerequisites ▪ The knife holder is removed from the knife revolver (Refer to the section
“Replacing the knife holder in the revolver” in this chapter for the detailed
procedure).

Tools required ▪ A set of Allen keys.

1. Slightly loosen the Allen screw (1).

Fig. 6-28 Replacing the knife

2. Pull the knife (2) out from the knife holder (3).

3. Insert the new knife into the knife holder.

4. Tighten the Allen screw (1).

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6 - Size part changeover and settings
Wall length cutting station

A new knife is approximately 33mm in length. Make sure that the

rear end of the knife (2) is approximately aligned with the knife
holder (up to 1.5mm acceptable). The knife should not protrude
from the knife holder at the back side.

3
2

Fig. 6-29 Rear side of the knife holder

■ End of the procedure.

6.8.4 Setting the knife revolver in the setting jig

The knives must be adjusted such that there is a gap of 145 microns between
the spacer roller and the tip of the knife. This is to prevent the knife from cutting
into the mandrel during the length cutting process. A setting jig is provided for
this purpose. When the machine is under production, the knives on the spare
knife revolver can be set up by using this setting jig. the new knife revolver
can then be at the cutting station after the current cutting knives are worn out.
This helps in a quick changeover of the cutting knives. The procedure for
setting the knife revolver in the setting jig is as follows:

Prerequisites ▪ All knives in the knife holders are replaced (Refer to the section “Replacing
the knives” in this chapter for the detailed procedure).

Tools required ▪ The setting jig is available.

▪ A set of Allen keys.

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6 - Size part changeover and settings
Wall length cutting station

Putting the revolver 1. Turn the knob (1) clockwise to move the locking plate (2) outwards.
into the setting jig

1 2

4
Fig. 6-30 Putting the revolver into the setting jig

2. Put the knife revolver (3) on the centering shaft (4).

3. Turn the knob (1) counterclockwise till the locking plate (2) is seated in the
notch (5) on the knife revolver.

Make sure that the heads of the shoulder bolts (6) are lifted off the
plate (7). This indicates that the locking plate is properly seated in
the notch on the knife revolver and the knife revolver is locked in
position.

5
2
7
6
1

Fig. 6-31 Locking the knife revolver

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6 - Size part changeover and settings
Wall length cutting station

Setting the knife 4. Make sure the knife (8) is clearly behind the spacer roller (9).

11
9

12 8

Fig. 6-32 Setting the knife

5. Rotate the knob (10) counter-clockwise till the roller face (11) just touches
the spacer roller (9).

When the roller face contacts the spacer roller, the needle of the
dial gauge (13) will not rotate even if you rotate the knob (10).

11 9
13

10

12
Fig. 6-33 Setting the knife

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6 - Size part changeover and settings
Wall length cutting station

6. Rotate the knob (10) by one more turn to make sure that the roller face
and the spacer roller are in contact.

7. Turn the adjusting screw (14) counter-clockwise. The knife (8) will move
outwards.
11
9
8

12

14 15
Fig. 6-34 Setting the knife

8. Turn the adjusting screw (14) till the knife (8) just touches the knife face
(12). The needle of the dial gauge (13) shows movement when the knife
touches the knife face.

Do not move the knife too forward. Moving the knife too forward
will result in a gap between the spacer roller (9) and the roller face
(11).

9. Tighten the Allen screw (15) to lock the knife in position.

While tightening the Allen screw, the needle of the dial gauge will
show some movement. This is normal. The needle of the dial gauge
must return to the position where it was before tightening the Allen
screw.

10. Check if the spacer roller and the knife are touching the roller faces and
knife face respectively. In case of a gap between any of these surfaces,
set the knife again.

The gap can be checked by using a backlight or a 10 micrometer

feeler gauge.

11. Repeat steps 1 through 10 for setting the other knives on the revolver.

■ End of the procedure.

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6 - Size part changeover and settings
Wall length cutting station

6.8.5 Adjusting the cutting knife-to-mandrel pressure

The cutting knife-to-mandrel pressure must be adjusted when the diameter
of the can changes. During the cutting process, the spacer roll remains in
contact with the mandrel. This will ensure that there is a gap between the
mandrel and the cutting edge of the knife, to prevent the knife from cutting into
the mandrel and for good quality cutting of the can. The procedure is as follows:

Prerequisites ▪ The machine is stopped.

▪ The front and side safety doors are open.
▪ The mandrels of the new size are installed.
▪ The machine is inched until the mandrel is at the wall length cutting station.
▪ The knives on the revolver are set in the setting jig (Refer to the section
“Setting the knife revolver in the setting jig” for the detailed procedure).
▪ The knife revolver is at its outermost position (away from the mandrel).
▪ The pressure rollers of the new size are installed.
▪ A sample can of the required size is available.

Tools required ▪ A set of Allen keys.

▪ A 145 micrometer feeler gauge.

1. On the PRODUCTION: Cutting screen, tap the Knife revolver INDEX

MANUAL key till the spacer roller No. 1 is at the cutting position. The spacer
rollers on the knife revolver are numbered from 1 to 4.

2. Insert a can (1) onto the mandrel (2).

Use the mandrel at the innermost position (closest to the centre of

the turret) as the reference mandrel for setting the spacer roller. The
innermost mandrel can be identified visually by observing the gap
between the spacer roll and the mandrel or by using a feeler gauge
between the spacer roller and the mandrel. The innermost mandrel
will show the maximum gap between the spacer roller and the
mandrel.

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6 - Size part changeover and settings
Wall length cutting station

3. On the PRODUCTION: Cutting screen, tap the More key next the Length
cut offset parameter. A pop-up window appears on the screen.

Fig. 6-35 Pop-up window

4. On the pop-up window, tap the Cutting length axis JOG BACKWARD key
till the cutting knife is approximately 5 to 15 mm away from the open end
of the can.

5. On the PRODUCTION: Cutting screen, tap the Pressure roller

ACTIVATE key to engage the pressure rollers.

6. On the PRODUCTION: Cutting screen, tap the More key next the Dia.
cut offset parameter. A pop-up window appears on the screen.

Fig. 6-36 Pop-up window

7. On the PRODUCTION: Cutting screen, set the required can diameter in

the Product dia.parameter.

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6 - Size part changeover and settings
Wall length cutting station

8. On the pop-up window, tap the Cutting diameter axis JOG FORWARD
key till the spacer roller (3) just touches the mandrel surface.

5 6

2
Fig. 6-37 Setting the knife-to-mandrel pressure

9. Visually check the contact between the spacer roller and the mandrel.
Make sure that there is a gap between the knife edge (4) and the mandrel.

10. To adjust the gap between the knife and the mandrel, loosen the Allen
screw (5).

11. Turn the adjusting screw (6) till there is a 145 micrometer gap between
the knife edge and the mandrel surface. Use the feeler gauge for this
purpose.

12. Tighten the Allen screw (5).

13. Repeat steps 1 through 11 for setting the other spacer rolls and knives.

■ End of the procedure.

6.8.6 Adjusting the wall cutting length

The position of the cutting tool must be adjusted when the length of the product
changes to ensure that the products are cut according to the required length.
The procedure is as follows:

Prerequisites ▪ The machine is in stopped condition.

▪ The front and side safety doors are open.
▪ The mandrels of the new size are installed.
▪ The knife revolver is installed at the wall length cutting station.
▪ The cutting knife-to-mandrel distance is set (Refer to the preceding section
for the detailed procedure).

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6 - Size part changeover and settings
Wall length cutting station

Tools required No tools are required.

1. On the PRODUCTION: Cutting screen, enter the required length of the

can in the Product length parameter.

2. Fine-tune the can length by adjusting the Length cut offset parameter.

■ End of the procedure.

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6 - Size part changeover and settings
De-burring station

6.9 De-burring station

6.9.1 Adjusting the de-burring roller
The de-burring roller has a spring-loaded mechanism, which keeps it pressed
against the product on the mandrel. If needed, the pressure exerted by the
roller against the product can be adjusted as follows:

Prerequisites ▪ The machine is stopped.

▪ The front and side safety doors are open.

Tools required ▪ A set of Allen keys and spanners

Pressure 1. Loosen the hex nut (1).

adjustment

2 1
4 5

Fig. 6-38 Adjusting the de-burring roller

2. Turn the hex nut (2) counter-clockwise to increase the pressure of the de-
burring roller (3) against the mandrel. Turn it clockwise to reduce the
pressure.

3. Tighten the hex nut (1).

Adjusting the de-burring 4. Loosen the Allen screw (4).

roller along the mandrel
length
5. Turn the spindle (5) to move the de-burring roller along the length of the
mandrel (Range of adjustment is 2-3mm).

6. Tighten the Allen screw (4).

■ End of the procedure.

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6 - Size part changeover and settings
Brushing station

6.10 Brushing station

6.10.1 Replacing the brush roller
If the brush roller is worn out, it can be replaced as follows:

Prerequisites ▪ The machine is stopped.

▪ The front and side safety doors are open.

Tools required A set of Allen keys.

1. Move the brushing station to its service position (Refer to the section
“Moving the brushing station to the service position” for the detailed
procedure).

2. Open the cover of the brushing station (Refer to the section “Removing
the covers of the brushing station” for the detailed procedure).

3. Loosen and remove the two Allen screws (1).

3
8
4

1
2

7
6 5

Fig. 6-39 Replacing the brush roller

4. Remove the clamping bracket (2).

5. Loosen and remove the four Allen screws (3).

6. Remove the clamping bracket (4).

7. Take the brush roller (5) out from the mounting blocks (6).

8. Place the new brush roller shaft on the mounting blocks (6).

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6 - Size part changeover and settings
Brushing station

9. Place the two clamping brackets (2) and (4) over the shaft ends. Make sure
that the key (7) on the brush roller shaft is seated in the slot (8) on the
clamping bracket.

10. Insert and tighten the two Allen screws (1).

11. Insert and tighten the four Allen screws (3).

■ End of the procedure.

6.10.2 Adjusting the brush roller against the mandrel

The brush roller can be adjusted against the mandrel as follows:

Prerequisites ▪ The machine is stopped.

▪ The front safety door is open.
▪ The mandrels of the new size are installed.

Tools required No tools are required.

1. Loosen the lock nut (1).

1
2

Fig. 6-40 Adjusting the brush roller against the mandrel

2. Turn the handwheel (2) to move the brush roller (3) up or down. Clockwise
rotation moves the brush roller down and counter-clockwise rotation
moves the brush roller up.

3. Tighten the lock nut (1).

4. Run the machine and check for proper brushing of the products.

5. Re-adjust the position of the brush roller, if necessary.

■ End of the procedure.

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6 - Size part changeover and settings
Brushing station

6.10.3 Angular adjustment of the brush roller

The brush roller can be adjusted at an angle to apply more or less pressure
at the outer end of the mandrel. The procedure is as follows:

Prerequisites ▪ The machine is in stopped condition.

▪ The front and side safety doors are open.
▪ The mandrels of the new size are installed.

Tools required A set of Allen keys.

1. Turn the adjusting spindle (1) to move the outer end of the brush roller (2)
up or down. Clockwise rotation moves the brush roller up and counter-
clockwise rotation moves the brush roller down.

1 2

Fig. 6-41 Angular adjustment of the brush roller

■ End of the procedure.

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6 - Size part changeover and settings
Brushing station

6.10.4 Adjusting the oscillation stroke of the brush roller

The oscillation stroke of the brush roller can be adjusted as follows:

Prerequisites ▪ The machine is stopped.

▪ The side safety door of the machine is open.

Tools required A set of Allen keys.

1. Turn the adjusting spindle (1) to adjust the oscillation stroke of the brush
roller (1). The oscillation stroke can be set from 10mm to 25mm.

Fig. 6-42 Adjusting the oscillation stroke of the brush roller

2. Use the markings on the ruler (2) as a reference for the adjustment.

■ End of the procedure.

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6 - Size part changeover and settings
Brushing station

6.10.5 Moving the brushing station to the service position

For setups and maintenance, the brushing station can be moved to its service
position as follows:

Prerequisites ▪ The machine is stopped.

▪ The front and side safety doors of the machine are open.

Tools required A set of Allen keys.

Moving the brushing 1. Turn the lever (1) up to unlock the brushing station (2).
station to the service
position

1 3

Fig. 6-43 Moving the brushing station to the service position

2. Pull the brushing station to its outermost position along the linear guides
(3).

Fig. 6-44 Brushing station at the service position

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6 - Size part changeover and settings
Brushing station

Moving the brushing 3. Push the brushing station to its innermost position in the machine along
station to the working the linear guides (3).
position

4
5

3 6

Fig. 6-45 Moving the brushing station to the working position

4. Make sure that the cam roller (4) is aligned with the slot (5) on the cam
lever (6).

5. Turn the lever (1) down to lock the brushing station (2).

■ End of the procedure.

6.10.6 Removing the covers of the brushing station

For setups and maintenance, the covers of the brushing station can be
removed as follows:

Prerequisites ▪ The machine is stopped.

▪ The front and side safety doors of the machine are open.

Tools required A set of Allen keys.

1. Move the brushing station to its service position (Refer to the section
“Moving the brushing station to the service position” for the detailed
procedure).

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6 - Size part changeover and settings
Brushing station

Removing the 2. Loosen the two knobs (1).

top cover

2
1

Fig. 6-46 Removing the top cover

3. Remove the top cover (2).

4. Unlock the toggle latches (3) and (4).

3 5

Fig. 6-47 Opening the main cover

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6 - Size part changeover and settings
Brushing station

5. Open the main cover (5). Hold the main cover in the open position by
hooking the latch plate (6) on the pin (7).

Fig. 6-48 Opening the main cover

Removing the main cover 6. Unhook the latch plate (6) from the pin (7).

7. Lift the main cover from the mounting slots (8).

6
5

9
8

Fig. 6-49 Removing the main cover

Installing the main cover 8. Mount the bolts (9) of the main cover in the slots (8) on the brushing station.

9. Close the main cover (5).

10. Lock the two toggle latches to secure the main cover to the brushing
station.

11. Place the cover (1) over the main cover.

■ End of the procedure.

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6 - Size part changeover and settings
Brushing station

6.10.7 Replacing the grindstone of the brush cleaning unit

The brush cleaning unit cleans the brush roller by means of a grindstone that
scrapes against the brush roller. This keeps the brush surface even and
uniform. If the grindstone is worn out, it must be replaced. The procedure is
as follows:

Prerequisites ▪ The machine is stopped.

▪ The front and side safety doors of the machine are open.

Tools required A set of Allen keys.

1. Move the brushing station to its service position (Refer to the section
“Moving the brushing station to the service position” for the detailed
procedure).

2. Open the main cover of the brushing station (Refer to the section
“Removing the covers of the brushing station” for the detailed procedure).

Fig. 6-50 Replacing the grindstone of the brush cleaning unit

3. Loosen the five Allen screws (1).

4. Remove the grindstone bar (2) from the holder (3).

5. Mount the new grindstone bar (2) into the holder (3). Make sure that the
plate (4) is above the grindstone bar.

6. Tighten the five Allen screws (1).

■ End of the procedure.

Operating Manual V1.0 Zelos 6-39

6 - Size part changeover and settings
Pressure rollers

6.11 Pressure rollers

The pressure roller at the wall length cutting station pushes the product towards
the cutting tool in order to ensure a clean cut throughout the circumference
of the product during the cutting process. The pressure roller at the brushing
stations press the product against the mandrels to prevent the products from
slipping on the mandrels during the brushing operation. The pressure rollers
must be changed when the mandrel diameter changes.

6.11.1 Changing the pressure rollers

When the mandrel diameter changes, the pressure rollers must be changed.
The procedure for changing the pressure rollers is as follows:

Prerequisites ▪ The machine is stopped.

▪ The front and side safety doors of the machine are open.
▪ The mandrels of the new size are installed on the machine.

Tools required A set of Allen keys.

Removing 1. Loosen and remove the Allen screw (2).

the roller

Fig. 6-51 Changing the pressure rollers

2
3
4

Fig. 6-52 Changing the pressure rollers

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6 - Size part changeover and settings
Pressure rollers

2. Remove the pressure roller (1) from the holder.

Installing 3. Mount the pressure roller of the required size on the holder. Make sure
the roller to align the pin (3) on the holder with the hole (4) on the roller.

4. Insert and tighten the Allen screw (2).

■ End of the procedure.

Operating Manual V1.0 Zelos 6-41

6 - Size part changeover and settings
Take-off unit

6.12 Take-off unit

6.12.1 Changing the product grippers
When the product diameter changes, the product grippers must be changed.
The product grippers are equipped with a quick locking mechanism for a fast
changeover.

2 3

Fig. 6-53 Changing the product grippers

Prerequisites ▪ The front safety door of the machine is open.

▪ The product grippers of the new size are available.

Tools required No tools are required.

1. Inch the machine to move the take-off unit to its outermost position.

2. Release the quick-connector (1) and remove the product gripper (2) from
the gripper arm (3).

3. Push the new product gripper into the gripper arm till the quick connector
locks the product gripper in position.

4. Repeat steps 1 through 3 for changing the remaining product grippers.

■ End of the procedure.

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6 - Size part changeover and settings
Take-off unit

6.12.2 Aligning the chain pegs to the product grippers

The chain pegs on the outfeed chain can be adjusted so that the chain pegs
at the unloading station are properly aligned with the product grippers. This
ensures a smooth unloading of products from the mandrels to the chain pegs
of the outfeed chain.

Prerequisite ▪ The front and side safety doors of the machine are open.
▪ The take-off grippers are aligned with the mandrels.
▪ Sample products of the required size are available.

Tools required A set of spanners.

1. Loosen the two hex bolts (1) by using a spanner.

Fig. 6-54 Aligning the chain pegs to the product grippers

2. Turn the screw (2) clockwise or counter-clockwise to move the outfeed

chain sprocket (3) along with the chain up or down.

Adjust till the three chain pegs at the unloading station are aligned
with the centres of the corresponding product grippers.

3. Tighten the two hex bolts (1) to secure the position of the outfeed chain
sprocket.

4. Inch the machine and check for the smooth transfer of products from the
take-off unit to the chain pegs; readjust if necessary.

■ End of the procedure.

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6 - Size part changeover and settings
Chain peg guiding devices

6.13 Chain peg guiding devices

During the take-off function, the chain pegs on which the products are placed
must be well-guided and supported by the chain peg guiding devices.

6.13.1 Adjusting the chain peg guiding wheel

The chain peg guiding wheel must be moved outward for shorter products to
provide more support to the chain pegs and inwards for longer products.

Prerequisite The front safety door of the machine is open.

Tools required A set of Allen keys

1. Loosen the set screw (1).

1 3 4

~5mm

Fig. 6-55 Adjusting the chain peg guiding wheel

2. Put a sample product (2) on the chain peg.

3. Move the guiding wheel (3) along the hollow shaft (4) to the correct position.

Keep the clearance between the product end and the wheel at
approximately 5 mm.

4. Tighten the set screw (1).

■ End of the procedure.

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6 - Size part changeover and settings
Chain peg guiding devices

6.13.2 Adjusting the chain peg guiding plate

The chain peg guiding plate (1) can be adjusted against the chain pegs to
support the chain pegs. The chain peg guiding plate must be re-adjusted when
it is not applying sufficient pressure on the chain pegs.

Prerequisite The front safety door of the machine is open.

Tools required A set of spanners.

1. Loosen the two hex nuts (1).

2
1

Fig. 6-56 Chain peg guiding plate

2. Move the chain guiding plate (2) up or down to the required position.

Move the chain guiding plate up to increase the pressure on the

chain pegs.

3. Tighten the two hex nuts (1).

■ End of the procedure.

Operating Manual V1.0 Zelos 6-45

6 - Size part changeover and settings
Stripper unit

6.14 Stripper unit

6.14.1 Changing the stripper plates
When the diameter of the product changes, the stripper plates must be
changed. The procedure is as follows:

Prerequisites ▪ The machine is stopped.

▪ The front and side safety doors are open.
▪ The stripper unit is at its uppermost position (away from the mandrel).
▪ The mandrels of the new size are installed in the machine.

Tools required A set of Allen keys.

1. Inch the machine till the stripper unit is at its uppermost position.

2. Loosen and remove the screws (1).

1
2

Fig. 6-57 Changing the stripper plates

3. Remove the stripper plates (2) from the brackets (3).

4. Mount new stripper plates onto the brackets. Do not interchange the
stripper plates. Mount the longer stripper plate at the first stripping station.
Make sure that the markings on the stripper plates face outwards.

5. Insert and slightly tighten the screws (1).

6. Inch the machine and inspect the stripper unit functioning.

7. Fine adjust the gap between the stripper plates and the mandrel (4) and
fully tighten the screws (1).

Ensure that there is no friction between the stripper plates and the
mandrel.

■ End of the procedure.

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6 - Size part changeover and settings
Stripper unit

6.14.2 Adjusting the end ring retaining brush

The end ring retaining brush needs to be adjusted to hold the end ring pushed
by the first stripper plate and prevent it from moving out of reach of the second
stripper plate. The procedure is as follows:

Prerequisites ▪ The machine is stopped.

▪ The front and side safety doors of the machine are open.
▪ The stripper unit is at its uppermost position (away from the mandrel).
▪ The mandrels of the new size are installed in the machine.

Tools required ▪ A set of spanners.

1. Loosen the hex screw (1).

2
1

Fig. 6-58 Adjusting the end ring retaining brush

2. Move the end ring retaining brush (2) up till it touches the mandrel (3).

3. Tighten the hex screw (1).

■ End of the procedure.

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6 - Size part changeover and settings
Scrap suction channel

6.15 Scrap suction channel

The scrap suction channel can be swivelled up for better access to the different
units during setups and maintenance. The procedure is as follows:

Prerequisites ▪ The machine is stopped.

▪ The front safety door of the machine is open.

Tools required No tools are required.

1. Pull the scrap suction channel (1) out and swivel it up. The scrap suction
channel is supported by the gas spring (2).

5
1

Fig. 6-59 Swivelling the scrap suction channel

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6 - Size part changeover and settings
Scrap suction channel

2. Swivel the scrap suction channel down to its working position till the slot
(3) on the plate (4) is seated over the pin (5). Also make sure that the ball
plungers (6) snap into the holes on the plate (4).

3
1

Fig. 6-60 Swivelling the scrap suction channel

■ End of the procedure.

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6 - Size part changeover and settings
Press transfer conveyor

6.16 Press transfer conveyor

The press transfer conveyor transports raw products from the impact extrusion
press to the intermediate drum. According to variations in the product diameter
or length, the following adjustments must be carried out at the press transfer
conveyor:

▪ Adjusting the guide plate (at the infeed)

▪ Adjusting the guide plate (at the outfeed)
▪ Changing the rollsheet (at the outfeed)
▪ Adjusting the rollsheet

6.16.1 Adjusting the guide plate (at the infeed)

The guide plate aligns the products dropped into the pockets of the press
transfer conveyor from the impact extrusion press. When the product length
changes, the guide plate must be adjusted to make sure that the product
presence sensor on the press transfer conveyor detects the product and the
product length check sensor does not detect the product.

Prerequisites Sample (unfinished) products of the new size are available.

Tools required No tools are required.

1. Open the safety cover (1) of the press transfer conveyor.

4
3

Fig. 6-61 Adjusting the guide plate (infeed)

2. Place a sample product (2) on the conveyor.

3. Loosen the clamping lever (3).

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6 - Size part changeover and settings
Press transfer conveyor

4. Adjust the end position of the guide plate (4) such that the product can be
detected by the product presence sensor (5) and by the product length
check sensor (6). Adjust the guide plate such that short products (7) that
are less than the minimum required length are not be detected by the
product length check sensor (6).

6
5
2
4

7
Fig. 6-62 Adjusting the guide plate (infeed)

5. Lock the clamping lever (3).

■ End of the procedure.

6.16.2 Adjusting the guide plate (at the outfeed)

The guide plate at the outfeed of the press transfer conveyor aligns the
products before they are dropped into the intermediate drum pockets. This
makes sure that the products are dropped at the correct position into the
intermediate drum pockets. The guide plate must be adjusted when the
product length changes.

Prerequisites Sample (unfinished) products of the new size are available.

Tools required No tools are required.

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6 - Size part changeover and settings
Press transfer conveyor

1. Place a sample product (1) in a pocket at the top of the press transfer
conveyor.

5
1

3 4

Fig. 6-63 Adjusting the guide plate (outfeed)

2. Turn the lever (2) till the pointer (3) is aligned with the required product
length mark on the indicator plate (4). The guide plate (5) moves in or out
depending on the selected product length.

■ End of the procedure.

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6 - Size part changeover and settings
Press transfer conveyor

6.16.3 Changing the roll sheet

The roll sheet (1) at the outfeed of the press transfer conveyor guides the
products from the starwheel to the intermediate drum. When you change to
a different product diameter, the roll sheet must be changed. The procedure
for changing the roll sheet is as follows:

Prerequisite ▪ The front safety door of the machine is open.

▪ The intermediate drum for the required product size is mounted.

Tools required No tools are required.

1. Pull the roll sheet (1) out from the mounting block (2).

Fig. 6-64 Changing the roll sheet - Press transfer conveyor

2. Slide the roll sheet of the required product size into the mounting block
(2) till the four ball plungers (3) snap into the slots (4) on the roll sheet guide
plate (5).

2 3
1

Fig. 6-65 Mounting the roll sheet

■ End of the procedure.

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6 - Size part changeover and settings
Press transfer conveyor

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7 - Maintenance
General information

7 Maintenance

7.1 General information

7.1.1 Safety notes
Before you start maintenance work on the machine, obey these safety
precautions:

▪ Set the main power switch of the machine or line in the “OFF” position and
make sure that the switch is locked in this position.
▪ Disconnect the machine from any source of pressurized media, such as
compressed air, and release all energy caught in the machine
components.
▪ Use only correct parts in the machine, use correct tools, and apply correct
torque during a maintenance procedure.
▪ Put back all the safety guards and covers after a maintenance task and
make sure if all the safety devices operate correctly before starting the
machine again.
▪ Let only approved personnel do maintenance work on the machine.

7.1.2 Maintenance schedule symbols

Symbol Frequency Maintenance after

Daily 24 operating hours

Weekly 168 operating hours

Monthly 720 operating hours

Quarterly 2160 operating hours

Half yearly 4320 operating hours

Yearly 8640 operating hours

7.1.3 Maintenance activity symbols

Symbol Activity

Mechanical maintenance work

Lubrication instructions

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7 - Maintenance
General information

7.1.4 Tools required for maintenance

▪ A set of Allen keys
▪ A standard tool box
▪ A torque wrench
▪ A mallet
▪ Some lint-free cloth

7.1.5 Lubricants used

The lubricants used in the machine are given below:

Lubricant Used in
Mobilux EP2 Grease or an ▪ Bearings in general
equivalent NLGI Grade 1 grease ▪ All rod end bearings
▪ Sliding shafts of dancer
▪ Take-off unit stroke shaft
▪ Guide rods of the take-off unit
▪ Guide rod of feeding pusher
▪ Grease nipples on the handwheel
Shell Omala S2G 220 or an ▪ Manifold unit – central oil reservoir
equivalent oil (ISO VG 220) Cam box
▪ Outfeed chain
Mobil SCH 630 or equivalent ▪ Spur gearbox
Smart Straw WD-40 or Rustkote ▪ Mandrel surface (for rust
943 prevention)
ENS grease ▪ Mandrel sleeves
OKS 250 paste ▪ Mandrel ends (which are in contact
with the mandrel sleeves)
Shell Morlina S2 BL 2 oil ▪ FESTO pneumatic service unit

NOTICE
Mixing of different lubricants can cause deterioration of lubricant
performance.
Deterioration of lubricant performance will cause damage to the
machine in general.
– Do not mix lubricants from different manufacturers.
– Do not use the wrong lubricant.
– Keep the lubricants away from sources of contamination.
– Keep the lubricants correctly identified (by name, grade and
manufacturer).

Before applying grease with brush, ensure that the surface of the
parts are clean.
Excess grease must be cleaned for better maintenance monitoring.

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7 - Maintenance
General information

7.1.6 Cleaning solvents used

The cleaning solvents used for different machine parts are given below:

Cleaning medium Suitable for machine part

NITRORIEDIDLO BEZ AROMAT S200LT Machine paint
Regular window cleaner with alcohol (Apply Touch panel
with soft microfibre cloth)
NITRORIEDIDLO BEZ AROMAT S200LT Chain board plexiglas
NITRORIEDIDLO BEZ AROMAT S200LT White plastic drum
NITRORIEDIDLO BEZ AROMAT S200LT Roll sheet
P-TH000965 and P-TH002004 / PPG Rubber roller
NITRORIEDIDLO BEZ AROMAT S200LT Laser sensor glass

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7 - Maintenance
Maintenance and lubrication schedules

7.2 Maintenance and lubrication schedules

DANGER
High voltage hazard.
Any contact with live parts leads to an immediate threat to life due to
electric shock. Damage to the insulation or individual components can
be lethal.
– Only a qualified and authorized electrician is allowed to work on
electrical equipment.
– Turn off the mains power switch and secure it with a padlock to
prevent any unintended restart of the machine.
– If there is damage to electrical insulation, immediately turn off the
mains power switch and repair the insulation.
– Before you start working on the electrical parts, make sure that the
parts are free of electrical power. Strictly comply with all the
mandatory safety procedures related to each of these steps:
- Unlocking
- Secure against switching on
- No voltage
- Short circuit and earthing
- Cover or safeguard any other connected electrical parts.
– Do not bridge any fuses.
– Keep moisture away from live electrical parts. This may lead to
short circuits.

WARNING
Moving machine components.
Risk of cutting, crushing or shearing of fingers or hand.
– Keep clear of moving or rotating parts of the machine.
– If these parts must be serviced, turn off and lock out the main power
switch to prevent any unexpected startup of the machine.

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7 - Maintenance
Maintenance and lubrication schedules

7.2.1 Daily maintenance

Position Location Activity Maintenance function

Machine in -- Clean the machine exterior
general and the different units.
Remove scrap, burrs and
excessive lubricants.
Safety switches -- Check all safety switches
for proper functioning.

Pneumatic -- Check for air leakage.

hoses, nipples,
valves
Air filter -- Drain condensed water
from the bottom of the filter
element. Drain condensed
water from the bottom of the
air reservoir.
Scrap extraction -- Empty the scrap and chips
unit from the scrap extraction
unit.
Mandrels -- Clean the mandrels.
If the mandrels are not used
for long, apply lubricant on
the mandrels to prevent
rust.
Roll sheet -- Clean the surface in contact
with the product with solvent
and a dry cloth.
Loading drum -- Clean the surface in contact
with the product with solvent
and a dry cloth.
Intermediate -- Clean the surface in contact
drum with the product with solvent
and a dry cloth.
Pressure rollers -- Clean the surface in contact
with the product with solvent
and a dry cloth.

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7 - Maintenance
Maintenance and lubrication schedules

7.2.2 Weekly maintenance

Position Location Activity Maintenance function

Outfeed chain -- Check for proper tension
and smooth functioning of
chains.
All rod end bearings -- Apply grease manually
with a grease gun.

Timing belt pulleys -- Clean and check for free

running.

Timing belts -- Check for tension and

damage.
Replace if worn out.
Safety switches -- Check all mechanical,
(including safety doors electrical and electronic
and E-stop push safety systems for
buttons) reliable functioning.
Sensors -- Clean with a dry cloth.

Vacuum pump -- Refer to the supplier's

manual for maintenance
instructions.
Press transfer conveyor (1) Clean the conveyor.
Open the cover (2) at the
bottom of the conveyor
and remove the cans.

1 2

Fig. 7-1 Press transfer conveyor

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7 - Maintenance
Maintenance and lubrication schedules

Interval: Weekly

Position Location Activity Maintenance function

Brushing station (3) Open the main cover (4)
of the brushing station
and remove dust from the
station.

Fig. 7-2 Brushing station

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7 - Maintenance
Maintenance and lubrication schedules

Interval: Weekly

Position Location Activity Maintenance function

Manifold unit (5) Make sure that the
lubrication pipes are
unclogged.

Fig. 7-3 Manifold unit

Position Location Activity Maintenance function

Mandrel drive belt -- Check the belt for wear.
Check the tension on the
belt.
Adjust the tension on the
belt. Replace the belt if
necessary.
Mandrel brake belt -- Check the belt for wear.
Check the tension on the
belt.
Replace the belt if
necessary.

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7 - Maintenance
Maintenance and lubrication schedules

7.2.3 Monthly maintenance

Position Location Activity Maintenance function

Guarding and -- Check the guarding and
protection covers protection covers and re-
tighten their fixing screws.
Chain sprockets -- Remove old and excess
grease from all chain
sprockets.
Rod end bearings -- Check all rod end bearings
for wear and play.

Electrical cabinet -- Clean with a vacuum

cleaner.

Press transfer (1) Apply grease on the chains

conveyor chains with a brush.

Bearings of the (2) Apply grease with a grease

conveyor chain gun on the grease nipples.
sprockets

1
2
Fig. 7-4 Press transfer conveyor - Chains and sprockets

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7 - Maintenance
Maintenance and lubrication schedules

Interval: Monthly

Position Location Activity Maintenance function

Guide blocks of the roll (3) and Apply grease with a
sheet (4) brush.

Fig. 7-5 Roll sheet

Position Location Activity Maintenance function

Brushing station (5) Apply grease with a
grease gun on the grease
nipples.

Fig. 7-6 Brushing station

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7 - Maintenance
Maintenance and lubrication schedules

Interval: Monthly

Position Location Activity Maintenance function

Grindstone of the (6) Check the grindstone for
brushing station wear. Adjust the position
of the grindstone for
proper cleaning of the
brush.

Fig. 7-7 Grind stone - Brushing station

Position Location Activity Maintenance function

Spur gear box (7) Check the oil level at the
sight glass and top-up if
required.

Fig. 7-8 Spur gear box

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7 - Maintenance
Maintenance and lubrication schedules

Interval: Monthly

Position Location Activity Maintenance function

Stripper unit (8) Apply grease with a
grease gun on the grease
nipples.

Fig. 7-9 Stripper unit

Position Location Activity Maintenance function

Timing belt of the take- (9) Check tension on the belt.
off unit Check the timing belt for
wear. Replace, if worn.
Suction cups of the take- (10) Check the suction cups
off unit for wear and air leaks.
Replace, if necessary.

1
Fig. 7-10 Take-off unit

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7 - Maintenance
Maintenance and lubrication schedules

Interval: Monthly

Position Location Activity Maintenance function

Central oil reservoir (11) Check the oil level in the
central oil reservoir. Top-
up, if required.

1

Fig. 7-11 Central oil reservoir

Position Location Activity Maintenance function

Bearing housing of (12) Apply grease with a
Pressure rollers at grease gun on the grease
cutting and brushing nipples.
stations.

12

12

Fig. 7-12 Bearing housing - Pressure rollers

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7 - Maintenance
Maintenance and lubrication schedules

7.2.4 Quarterly maintenance

Position Location Activity Maintenance function

Control cabinet and -- Check all electrical
electrical systems connections.

Outfeed chain -- Apply lubricant

manually with a brush.

Drive belt of the oil (1) Check tension on the

pump drive belt. Check belt for
wear. Replace, if worn
out.

Fig. 7-13 Drive belt of the oil pump

Position Location Activity Maintenance function

Bushing of mandrel 2 Apply ENS grease with a
sleeve grease gun (1.4- 1.8 cc
per mandrel bushing)

Fig. 7-14 Mandrel bushing (representative image)

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7 - Maintenance
Maintenance and lubrication schedules

7.2.5 Half yearly maintenance

Position Location Activity Maintenance

function
Feeding pusher (1) Check the
unit feeding pusher
unit for play. In
case of
excessive play,
replace the
plastic bushes
(2) of the feeding
pusher unit.


2

Fig. 7-15 Feeding pusher unit

Position Location Activity Maintenance function

Stripper unit (3) Check the stripper unit for
play. In case of excessive
play, replace the plastic
bushes (4) of the stripper
unit.

4
4
3

Fig. 7-16 Stripper unit

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7 - Maintenance
Maintenance and lubrication schedules

Interval: Half yearly

Position Location Activity Maintenance function

Central oil reservoir (5) Drain the oil completely
and fill the reservoir with
new oil.

Fig. 7-17 Central oil reservoir

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7 - Maintenance
Maintenance and lubrication schedules

7.2.6 Yearly maintenance

Position Location Activity Maintenance function

Guarding and -- Take out the protection
protection covers covers and clean them
thoroughly.
Transport chains -- Clean with a stiff wire
brush.
Check the chain over its
whole length for bent
pegs and replace
damaged pegs if any.
Lubricate the chain.
Chain sprockets -- Closely inspect each
chain sprocket for wear.
Turn each individual
sprocket by hand to check
its smooth functioning.
Replace the sprockets or
its bearings if increased
resistance is found.
Bushes and -- Check for wear.
bearings Replace if required.

Drive chains at the -- Check tension on the

machine rear chains. Check for
elongation. Replace, if
necessary.

Operating Manual V1.0 Zelos 7-17

7 - Maintenance
Maintenance and lubrication schedules

Interval: Yearly

Position Location Activity Maintenance function

Spur gear box (1) Refer to the supplier’s
manual for the type of
lubricant to be used and
the lubricating
instructions to be
followed.

Fig. 7-18 Spur gear box

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7 - Maintenance
Maintenance activities

7.3 Maintenance activities

7.3.1 Replacing the mandrel drive belt
The mandrel drive belt can be replaced as follows:

Prerequisites ▪ The machine is stopped.

▪ The safety doors of the machine are open.

Tools required A set of spanners.

1. Loosen the two bolts (1).

2. Loosen the screw (2) by using a spanner to relieve the tension in the belt (3).
8
1
7
2
6
3
5
4

10

9
1
2 4
8 1
5

Fig. 7-19 Replacing the mandrel drive belt

3. Pull out the mandrel drive belt (3) from the pulleys (4) to (10).

4. Mount the new mandrel drive belt on the pulleys (4) to (10). Thread the
mandrel drive belt over the mandrel sleeves from stations 4 to 8.

5. Tighten the belt by tightening the screw (2).

6. Tighten the two bolts (1).

■ End of the procedure.

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7 - Maintenance
Maintenance activities

7.3.2 Replacing the mandrel brake belt

The mandrel brake belt can be replaced as follows:

Prerequisites ▪ The machine is stopped.

▪ The safety doors of the machine are open.

Tools required No tools are required.

1. Pull the mandrel brake belt (1) out from the pulleys (2) and (3).

Fig. 7-20 Replacing the mandrel brake belt

2. Mount one end of the new mandrel brake belt on the pulley (2).

3. Thread the new mandrel brake belt over the mandrel sleeves from stations
9 to 3.

4. Mount the other end of the mandrel brake belt on the pulley (3).

■ End of the procedure.

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7 - Maintenance
Maintenance activities

7.3.3 Repairing the damaged edge of the knife

If the edge of the cutting knife is worn-out or damaged, the edge can be repaired
by the following procedure:

Prerequisites ▪ The worn-out knife is removed from the knife revolver.

Tools required ▪ Sharpening stone (oil stone) of grit grade 200 (for rough polishing)
▪ Sharpening stone (oil stone) of grit grade 1000 (for fine polishing)
▪ Polish paper of grit grade 1200 (for fine polishing)
▪ Thin oil or diesel
▪ Some lint-free cloth

1. Remove the damaged edge of the knife, by grinding the worn-out edge
against a sharpening stone (grade 200). Take care to retain the shape
(radius) of the knife edge.

Fig. 7-21 Repairing the knife - Remove damaged edge

2. Form a thin cutting edge by grinding the knife against the sharpening stone
(grade 200). Take care to keep the angle and shape of the knife edge same
as the original.Polish the knife in the direction as shown.

Fig. 7-22 Repairing the knife - Shape the cutting edge

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7 - Maintenance
Maintenance activities

3. Refine the cutting edge by grinding the knife against the sharpening stone
(grade 1000). From this step until the end of this procedure:
▪ Use thin oil or diesel to improve the results.
▪ Take care to keep the angle and shape of the knife edge same as the
original.

Fig. 7-23 Repairing the knife - Refine the cutting edge

4. Turn the knife around and repeat the process in the previous step to remove
the burrs on the edge.

5. Finish the cutting edge by grinding the knife against the polish paper (grade
1200). Place a cloth underneath the paper for a cushioning effect.

Fig. 7-24 Repairing the knife - Refine the cutting edge

6. Turn the knife around and repeat the process in the previous step to remove
the burrs on the edge.

■ End of the procedure.

7-22 Zelos Operating Manual V1.0

8 - Troubleshooting
About troubleshooting

8 Troubleshooting

8.1 About troubleshooting

This chapter consists of two parts:

▪ A list of all possible errors that may occur during the operation of the
machine, and the recommended steps to eliminate such errors.
▪ A list of the common quality issues concerning the end products of the
machine and the recommended ways to resolve such issues.

WARNING
Improper troubleshooting hazard!
Improper execution of a troubleshooting procedure can cause serious
injury and may also lead to substantial property damage.
– Eliminate the electrical faults and mechanical disturbances only
in accordance with the instructions contained in the operating
manual.
– Ensure that all fixed safety guards and covers are reinstalled and
the safety interlock devices are active before restarting the
machine.
– Comply with the local regulations and organisational measures on
industrial safety.

8.1.1 Description of error levels

Error level What it means

E-Stop Emergency stop Emergency stop ramp for individual axes
(unsynchronized) with drives de-energized,
triggered by Emergency stop activation.
M-Stop Mechanical stop Fast stop ramp for individual axes
(unsynchronized), triggered by alarm.
F-Stop Fast stop Fast stop ramp in position synchronization of all
axes (synchronized), triggered by alarm.
R-Stop Run stop Normal machine stop in home position
(synchronized), triggered by alarm.
Info Information Information about the machine state for which little
or no manual intervention is required.
Warning Warning message Alert about an active or approaching alarm /
machine condition that requires active intervention
by the user. Not heeding to the warning will lead to
an R-stop of the machine.

Operating Manual V1.0 Zelos 8-1

8 - Troubleshooting
Error messages

8.2 Error messages

Error Message Class Reason/ Remedy
No.
1001 Main cabinet e- E-Stop Reason:
stop - Emergency stop button
electric cabinet pressed
Remedy:
- Check emergency switch
S2641
1002 Main cabinet: F-Stop Remedy:
power supply - Check the incoming line 3
under voltage phase power supply
- Check the power
monitoring A1004
1003 Main cabinet: F-Stop Remedy:
power supply over - Check the incoming line 3
voltage phase power supply
- Check the power
monitoring A1004
1004 Main cabinet: F-Stop Reason:
surge protection - Incoming power surge
not ok protection faulty
Remedy:
- Check / replace protection
unit Z1003, Z1016, Z1018
1005 Main cabinet: F-Stop Remedy:
breaker smart line - Check Sinamics Infeed
module U1121 not Module U1121
ok - Check Breaker Q1015
1006 Main cabinet: F-Stop Remedy:
smart line module - Check Sinamics Infeed
U1121 fault Module U1121
- Check line supply voltage
- Check 24V control supply
voltage
1007 Main cabinet: F-Stop Remedy:
smart line module - Check Sinamics Infeed
U1121 alarm Module -U1121
- Check line supply voltage
- Check 24V control supply
voltage
1008 Main cabinet: F-Stop Remedy:
smart line module - Check Sinamics Infeed
U1121 not ready Module U1121
- Check line supply voltage
- Check 24V control supply
voltage

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8 - Troubleshooting
Error messages

Error Message Class Reason/ Remedy

No.
1009 Main cabinet: Warning Remedy:
breaker auxiliary - Check machine lighting,
not ok power sockets and main
cabinet cooling fan
- Check Breaker F1051,
Q1061, Q1071, F1081
1010 Main cabinet: F-Stop Remedy:
breaker 24Vdc not - Check 24V distribution in
ok electric main cabinet
- Check Breaker F1101
1011 Main cabinet: F-Stop Remedy:
breaker drives - Check 24V supply to drives
24Vdc not ok - Check Breaker F1043
1012 Main cabinet: F-Stop Reason:
sinamic integrated - Sinamics integrated in
profibus fault D435 controller offline
Remedy:
- Check Simotion controller
D435 A2381 - Re-boot
control
1013 Main cabinet: F-Stop Reason:
safety PLC A2601 - Safety PLC main electric
profinet fault cabinet A2601 profinet
offline
Remedy:
- Check profinet connection
PN/IO - cables - connectors
1014 Main cabinet: F-Stop Reason:
control unit A2383 - SINAMICS S120 controller
profinet fault main electric cabinet A2383
profinet offline Remedy
- Check profinet connection
PN/IO - cables - connectors
1015 Main cabinet: F-Stop Reason:
control unit A2391 - SINAMICS S120 controller
profinet fault main electric cabinet A2391
profinet offline Remedy
- Check profinet connection
PN/IO - cables - connectors
1024 Main cabinet: F-Stop Reason:
remote io A2561 - Remote I/O module main
profinet fault electric cabinet A2561
profinet offline
Remedy:
- Check profinet connection
PN/IO - cables - connectors

Operating Manual V1.0 Zelos 8-3

8 - Troubleshooting
Error messages

Error Message Class Reason/ Remedy

No.
1025 Ethernet Warning Reason:
connection to - TCP/IP communication
DECO offline between Front CPU and
DECO no connection.
Remedy:
- Check LAN connection
between cabinet.
- Check Switch (Hub)
working.
1026 Ethernet Warning Reason:
connection to - TCP/IP communication
DECO offline between Front CPU and
CALA no connection.
Remedy:
- Check LAN connection
between cabinet.
- Check Switch (Hub)
working.
1028 Data extraction: Info --
Event buffer
overflow
1032 Main cabinet: e- E-Stop Reason:
stop output not - Emergency stop circuit is
active not energised
Remedy:
- Reset Alarms
- Check Emergency Stop
Buttons
1034 Safety io error F-Stop Reason:
- Safety channels of fail-safe
module back to normal
condition
Remedy:
- Push reset to re-integrate
the particular module
1036 Main cabinet: Warning Reason:
safety module - Discrepancy between 2
A2603 deactivated safety channels (loops)
Remedy:
- Push and reset emergency
stop buttons
- Open and close doors
- Press and release
deadman switch
- Check emergency stop,
door and deadman switches
and wiring

8-4 Zelos Operating Manual V1.0

8 - Troubleshooting
Error messages

Error Message Class Reason/ Remedy

No.
1037 Main cabinet: Warning Reason:
safety module - Discrepancy between 2
A2605 deactivated safety channels (loops)
Remedy:
- Push and reset emergency
stop buttons
- Open and close doors
- Press and release
deadman switch
- Check emergency stop,
door and deadman switches
and wiring
1038 Main cabinet: Warning Reason:
safety module - Discrepancy between 2
A2606 deactivated safety channels (loops)
Remedy:
- Push and reset emergency
stop buttons
- Open and close doors
- Press and release
deadman switch
- Check emergency stop,
door and deadman switches
and wiring
1039 ZELOS Info --
- Washer:
Individual run
1050 Main cabinet: F-Stop
breaker 400Vac Remedy:
ZELOS not ok - Check 400V AC supply to
ZELOS Machine
- Check Breaker Q1021
1051 Main cabinet: F-Stop
breaker 24Vdc Remedy:
ZELOS machine - Check 24V DC supply to
not ok ZELOS Machine
- Check Breaker F1102
1052 ZELOS electric R-Stop
box: breaker Remedy:
400Vac not ok - Check ZELOS 400V AC
distribution
- Check Breaker Q3001,
Q3003, Q3005, Q3007,
Q3011, Q3017, Q3021,
Q3025, Q3031, Q3033

Operating Manual V1.0 Zelos 8-5

8 - Troubleshooting
Error messages

Error Message Class Reason/ Remedy

No.
1053 ZELOS electric R-Stop Remedy:
box: breaker turret - Check 200V AC supply to
worm gear fan or ZELOS Machine
knife revolver - Check external fan main
motor not ok gear or motor knife revolver
- Check Breaker
F3013,F3017
1054 ZELOS electric F-Stop Reason:
box: io module - Remote I/O module ZELOS
A3561 profinet terminal box A3561 profinet
fault offline
Remedy:
- Check profinet connection
PN/IO - cables - connectors
1055 Press machine e- F-Stop Reason:
stop - Emergency stop from press
machine
Remedy:
- Check emergency stop
button at press machine
1056 ZELOS machine e- E-Stop Reason:
stop - Emergency stop button
ZELOS machine pressed
Remedy:
- Check emergency switch
S3731
1057 ZELOS operating E-Stop Reason:
panel e-stop - Emergency stop button
ZELOS operator panel
pressed
Remedy:
- Check emergency switch
S3733
1058 Accu ZELOS E-Stop Reason:
operating panel e- - Emergency stop button
stop ACCU ZELOS operator
panel pressed
Remedy:
- Check emergency switch
S5331
1059 Laser unit e-stop E-Stop Reason:
- Emergency stop from laser
control unit
Remedy:
- Check laser control unit

8-6 Zelos Operating Manual V1.0

8 - Troubleshooting
Error messages

Error Message Class Reason/ Remedy

No.
1062 ZELOS machine Warning Reason:
door air pressure - Air pressure supply not
low sufficient
Remedy:
- Check air pressure supply
and valves
1063 ZELOS deadman Info Reason:
switch active - Door safety bypassed by
deadman switch
1064 ZELOS machine F-Stop Reason:
air pressure low - Air pressure supply not
sufficient
Remedy:
- Check air pressure supply
and valves
- Check pressure switch
S4111
1065 ZELOS accu e- E-Stop Reason:
Stop - Emergency stop button
ACCU ZELOS Machine
pressed
Remedy:
- Check emergency switch
S5333
1066 ZELOS electric Warning Reason:
box: safety module - Discrepancy between 2
A3563 deactivate safety channels (loops)
Remedy:
- Push and reset emergency
stop buttons
- Open and close doors
- Press and release
deadman switch
- Check emergency stop,
door and deadman switches
and wiring
1067 ZELOS electric Warning Reason:
box: safety module - Discrepancy between 2
A3564 deactivate safety channels (loops)
Remedy:
- Push and reset emergency
stop buttons
- Open and close doors
- Press and release
deadman switch
- Check emergency stop,
door and deadman switches
and wiring

Operating Manual V1.0 Zelos 8-7

8 - Troubleshooting
Error messages

Error Message Class Reason/ Remedy

No.
1068 ZELOS electric Warning Reason:
box: safety module - Discrepancy between 2
A3565 deactivate safety channels (loops)
Remedy:
- Push and reset emergency
stop buttons
- Open and close doors
- Press and release
deadman switch
- Check emergency stop,
door and deadman switches
and wiring
1070 ZELOS product Info Reason: - Production
quantity reached counter reached required
number
1072 Washing machine R-Stop Reason:
not ready - Washing machine stopped
or not ready.
Remedy:
- Start washing machine.
- Switch off "line mode" at
washing machine for testing.
1075 ZELOS press Door Reason:
transfer top cover - ZELOS press transfer top
open cover open
Remedy:
- Check cover switch -S3851
1076 ZELOS press Door Reason:
transfer middle - ZELOS press transfer
cover open middle cover open
Remedy:
- Check cover switch -S3853
1077 ZELOS press Door Reason:
transfer low cover - ZELOS press transfer
open middle cover open
Remedy:
- Check cover switch -S3855
1078 ZELOS left-front Door Reason:
door open - ZELOS left front door open
Remedy:
- Check door switch S3833
1079 ZELOS right-front Door Reason:
door open - ZELOS right front door
open
Remedy:
- Check door switch S3835
1080 ZELOS press Door --
guarding open

8-8 Zelos Operating Manual V1.0

8 - Troubleshooting
Error messages

Error Message Class Reason/ Remedy

No.
1081 ZELOS doors Door --
locked
1082 ZELOS front door Door Reason:
open - ZELOS front door open
Remedy:
- Check door switch S3831
1085 ZELOS rear door Door Reason:
open - ZELOS rear door open
Remedy:
- Check door switch S3845
1086 ZELOS left-rear Door Reason:
door open - ZELOS left rear door open
Remedy:
- Check door switch S3841
1087 ZELOS right-rear Door Reason:
door open - ZELOS left rear door open
Remedy:
- Check door switch S3843
1088 ZELOS door cycle R-Stop Reason:
not ok - All doors closed but door
safety not active
Remedy:
- Check door switches
S3831, S3833, S3835,
S3841, S3843, S3845
1089 ZELOS door open R-Stop Reason:
while machine - ZELOS door opened while
running machine running
Remedy:
- Use stop button to stop
machine
1100 ZELOS electric F-Stop Reason:
box: remote io - Remote I/O module ZELOS
A3561 profinet terminal box -A3561 profinet
fault offline
Remedy:
- Check profinet connection
PN/IO
- cables
- connectors

Operating Manual V1.0 Zelos 8-9

8 - Troubleshooting
Error messages

Error Message Class Reason/ Remedy

No.
1103 ZELOS oil Warning Reason:
pressure low - ZELOS oil pressure not
warning sufficient (Warning)
Remedy:
- Check oil pump and piping
- Check oil pump rotates
when machine runs
- Check pressure switch
S4112
1104 ZELOS oil R-Stop Reason:
pressure low alarm - ZELOS oil pressure not
sufficient for long time
Remedy:
- Check oil pump and piping
- Check oil pump rotates
when machine runs
- Check pressure switch
S4112
1106 ZELOS pusher jam F-Stop Remedy:
- Check ZELOS loading
station for jammed products
- Reset pusher back to
working position
- Check sensor B4211
1107 ZELOS mandrel F-Stop Reason:
ejector not in safe - The mandrel ejector is not
position in back position.
Remedy:
- Bring mandrel ejector to its
back position.
- Check sensor B4113.
1108 ZELOS mandrel R-Stop Reason:
not in position - No mandrel was detected in
one station.
Remedy:
- Check all mandrels are
present and for properly
engaged.
- Check sensor B4114.

8-10 Zelos Operating Manual V1.0

8 - Troubleshooting
Error messages

Error Message Class Reason/ Remedy

No.
1109 ZELOS product F-Stop Reason:
not unload - Product is not fully unload
from mandrel
Remedy:
- Check and re-engage flap
on chip remove suction head
- Check cable connected or
not
- Check proximity switch
S4414
1110 ZELOS scrap R-Stop Reason:
channel not closed - Scrap suction channel not
closed or not completely
locked.
Remedy:
- Close and lock the suction
chute.
- Check sensor -B4115
1111 ZELOS unloading F-Stop Reason:
output cam setting - Cam processing for take-
error off or mandrel airblow
started an error
Remedy:
- Correct unloading valve
setting value
1116 Upstream reduce Info --
speed - accu level
1117 Accu Washer no R-Stop Reason:
capacity - Press - Accu Washer will be full
stop when all products from
Trimmer entered
1118 ZELOS short Info Reason:
product detect -> - Product from Press
reject will be machine too short.
perform - ZELOS Loading unit
working not properly.
- Sensor setting not properly.
Remedy:
- Check Press machine.
- Check ZELOS loading unit.
- Check sensor setting
B4215.

Operating Manual V1.0 Zelos 8-11

8 - Troubleshooting
Error messages

Error Message Class Reason/ Remedy

No.
1119 ZELOS Bottom F-Stop Reason:
forming over clutch - Mechanical jam at bottom
not ok forming station
Remedy:
- Check for any jam or stuck
at bottom forming station
- Check overload clutch
sensor B4372
1120 ZELOS Bottom F-Stop Reason:
forming jam - Mechanical or product jam
at bottom forming station
Remedy:
- Check for any jam or stuck
at bottom forming station
- Check sensor B4371
1132 ZELOS turret drive F-Stop Reason:
fault no. ##### - Sinamics S120 drive
U1151 Fault
Remedy:
- Look-up Fault code in
SINAMICS List Manual
- Check Drive, Motor and
Wiring
1133 ZELOS turret drive F-Stop Reason:
alarm no. ##### - Sinamics S120 drive
U1151 Alarm
Remedy:
- Look-up Fault code in
SINAMICS List Manual
- Check Drive, Motor and
Wiring
1134 ZELOS turret first F-Stop Reason:
axis error no. - First Simotion Axis U1151
##### Error
- Error caused drive to stop
Remedy:
- Look-up Fault code in
SIMOTION Manual
1135 ZELOS turret F-Stop Reason:
second axis error - Second Simotion Axis
no. ##### U1151 Error
- Following Error
Remedy:
- Look-up Fault code in
SIMOTION Manual

8-12 Zelos Operating Manual V1.0

8 - Troubleshooting
Error messages

Error Message Class Reason/ Remedy

No.
1136 ZELOS turret first F-Stop Reason:
following object - First Simotion Following
error no. Axis U1151 Error
- Error caused drive to stop
Remedy:
- Look-up Fault code in
SIMOTION Manual
1137 ZELOS turret F-Stop Reason:
second following - Second Simotion Following
object error no. Axis U1151 Error
- Following Error
Remedy:
- Look-up Fault code in
SIMOTION Manual
1138 ZELOS turret F-Stop Reason:
reference sensor - U1151 Reference sensor
not found not found within specified
path length
Remedy:
- Check reference sensor -
B4101 and activation disk
- Check mechanics of
machine
- Check Input DI9 at D435 (-
A2381) terminal X122:10
1139 ZELOS turret F-Stop Reason:
motion timeout - U1151 Drive did not
respond to power on or
motion command
Remedy:
- Check for pending drive
alarms
- Check main supply and
infeed module
1140 ZELOS turret axis F-Stop Reason:
command error no. - U1151 Technology Object
##### command error Remedy
- Look-up Fault code in
SIMOTION Manual
1141 ZELOS turret not Info Reason:
referenced - Drive U1151 axis
coordinates not aligned
Remedy:
- Run reference function in
Setup Mode
- Start machine in Automatic
mode

Operating Manual V1.0 Zelos 8-13

8 - Troubleshooting
Error messages

Error Message Class Reason/ Remedy

No.
1142 ZELOS turret is Info Reason:
referencing - Movement to find reference
position running
1143 ZELOS turret Warning
safety circuit test Remedy:
required - Open and close safety
enclosure (door)
- Press emergency stop
button and reset
1144 ZELOS turret F-Stop Reason:
hardware limit - Hardware limit switch in
switch negative negative direction exceeded
Remedy:
- Check limit switch
- Move axis in positive
direction
1145 ZELOS turret F-Stop Reason:
hardware limit - Hardware limit switch in
switch positive positive direction exceeded
Remedy:
- Check limit switch
- Move axis in negative
direction
1146 ZELOS turret F-Stop Reason:
software limit - Software limit in negative
switch negative direction exceeded
Remedy:
- Move axis in positive
direction
1147 ZELOS turret F-Stop Reason:
software limit - Software limit switch in
switch positive positive direction exceeded
Remedy:
- Move axis in negative
direction
1148 Press machine Warning Reason:
offline - Upstream Press offline but
punching mode active
Remedy:
- Remove fault condition on
press and bring back to Auto
mode
- Deactivate punching mode
1149 Press machine not Warning Remedy:
ready - Remove fault condition on
press

8-14 Zelos Operating Manual V1.0

8 - Troubleshooting
Error messages

Error Message Class Reason/ Remedy

No.
1150 Press machine F-Stop Reason:
start timeout - ZELOS started
synchronization but press
did not respond
Remedy:
- Check press is ready to
start
- Check interface signals
K2821, K2822, K2823,
K2824
1151 Press machine F-Stop Reason:
synchronisation - ZELOS started
timeout synchronization but press
did not respond
Remedy:
- Check press is ready to
start
- Check interface signals
K2821, K2822,K2823,
K2824
1152 Press machine not Info --
active
1153 Press machine not Warning --
ready
1156 Press machine first F-Stop Reason:
encoder error no. - First Simotion Encoder
##### G4451 Error
Remedy:
- Look-up Fault code in
SIMOTION Manual
1157 Press machine F-Stop Reason:
second encoder - Second Simotion Encoder
error no. ##### G4451 Error
- Following Error
Remedy:
- Look-up Fault code in
SIMOTION Manual
1158 Press machine F-Stop Reason:
encoder command - G4451 Technology Object
error no. ##### command error
Remedy:
- Look-up Fault code in
SIMOTION Manual

Operating Manual V1.0 Zelos 8-15

8 - Troubleshooting
Error messages

Error Message Class Reason/ Remedy

No.
1159 Press machine F-Stop Reason:
encoder enable - G4451 Encoder did not
timeout respond to enable command
Remedy:
- Check for pending encoder
alarms
- Check encoder,
connectors and cables
1160 Press machine F-Stop Reason:
encoder reference - G4451 Reference sensor
sensor not found or Encoder zero mark not
found within specified path
length
Remedy:
- Check Encoder or Replace
1161 Press machine Info Reason:
encoder not - Encoder G4451 axis
referenced coordinates not aligned
Remedy:
- Start upstream press in
Manual or Automatic mode
1162 Press machine Info Reason:
encoder is - Movement to find reference
referencing position running
1203 ZELOS infeed F-Stop Remedy:
conveyor overload - Check and re-engage
overload clutch on ZELOS
infeed conveyor
- Check limit switch S4284
1204 ZELOS infeed R-Stop Remedy:
spring missing - Check spring on conveyor
- Check sensor -B4288
1205 ZELOS infeed R-Stop --
cannot follow
press: Product
present
1206 ZELOS infeed Info --
follows press
1207 ZELOS infeed in Info --
manual mode
1209 ZELOS Infeed R-Stop Remedy:
sync to turret time - Try to start machine again.
out - Try to Reference machine
again.
1210 ZELOS upstream F-Stop --
accu vacuum
supply not ok

8-16 Zelos Operating Manual V1.0

8 - Troubleshooting
Error messages

Error Message Class Reason/ Remedy

No.
1211 ZELOS upstream F-Stop --
accu drum
overload
1215 ZELOS infeed R-Stop --
conveyor flap open
1216 ZELOS infeed F-Stop Reason:
drive fault no. - Sinamics S120 drive
##### U1211 Fault
Remedy:
- Look-up Fault code in
SINAMICS List Manual
- Check Drive, Motor and
Wiring
1217 ZELOS infeed F-Stop Reason:
drive alarm no. - Sinamics S120 drive
##### U1211 Alarm
Remedy:
- Look-up Fault code in
SINAMICS List Manual
- Check Drive, Motor and
Wiring
1218 ZELOS infeed 1st F-Stop Reason:
axis error no. - First Simotion Axis U1211
##### Error
- Error caused drive to stop
Remedy:
- Look-up Fault code in
SIMOTION Manual
1219 ZELOS infeed 2nd F-Stop Reason:
axis error no. - Second Simotion Axis
##### U1211 Error
- Following Error
Remedy:
- Look-up Fault code in
SIMOTION Manual
1220 ZELOS infeed 1st F-Stop Reason:
following object - First Simotion Following
error no. ##### Axis U1211 Error
- Error caused drive to stop
Remedy:
- Look-up Fault code in
SIMOTION Manual

Operating Manual V1.0 Zelos 8-17

8 - Troubleshooting
Error messages

Error Message Class Reason/ Remedy

No.
1221 ZELOS infeed 2nd F-Stop Reason:
following object - Second Simotion Following
error no. ##### Axis U1211 Error
- Following Error
Remedy:
- Look-up Fault code in
SIMOTION Manual
1222 ZELOS infeed R-Stop Reason:
reference sensor - U1211 Reference sensor
not found not found within specified
path length
Remedy:
- Check reference sensor -
B4281 and activation disk
- Check mechanics of
machine
- Check Input DI09 at CU320
(A2383) terminal X122:10
1223 ZELOS infeed R-Stop Reason:
motion timeout - U1211 Drive did not
respond to power on or
motion command
Remedy:
- Check for pending drive
alarms
- Check main supply and
infeed module
1224 ZELOS infeed F-Stop Reason:
torque limit - Servo motor run at torque
exceeded limit.
Remedy:
- Check mechanical system
for jam or excessive friction.
1225 ZELOS infeed not Info Reason:
referenced - Drive U1211 axis
coordinates not aligned
Remedy:
- Run reference function in
Setup Mode
- Start machine in Automatic
mode
1226 ZELOS infeed Info Reason:
referencing - Movement to find reference
position running

8-18 Zelos Operating Manual V1.0

8 - Troubleshooting
Error messages

Error Message Class Reason/ Remedy

No.
1227 ZELOS infeed Warning Remedy:
safety circuit test - Open and close safety
required enclosure (door)
- Press emergency stop
button and reset
1232 ZELOS upstream F-Stop --
accu drive fault no.
#####
1233 ZELOS upstream F-Stop --
accu drive alarm
no. #####
1234 ZELOS upstream F-Stop --
accu 1st axis error
no. #####
1235 ZELOS upstream F-Stop --
accu 2nd axis error
no. #####
1236 ZELOS upstream F-Stop --
accu 1st following
object error no.
#####
1237 ZELOS upstream F-Stop --
accu 2nd following
object error no.
#####
1238 ZELOS upstream F-Stop --
accu reference
sensor not found
1239 ZELOS upstream F-Stop --
accu motion
timeout
1240 ZELOS upstream F-Stop --
accu torque limit
exceeded
1241 ZELOS upstream F-Stop --
accu not
referenced
1242 ZELOS upstream F-Stop --
accu referencing
1243 ZELOS upstream F-Stop --
accu safety circuit
test required
1259 Indexing drum R-Stop Remedy:
sync to turret time - Try to start machine again.
out - Try to Reference machine
again.

Operating Manual V1.0 Zelos 8-19

8 - Troubleshooting
Error messages

Error Message Class Reason/ Remedy

No.
1266 Indexing drum F-Stop Reason:
drive fault no. - Sinamics S120 drive
##### U1161 Fault
Remedy:
- Look-up Fault code in
SINAMICS List Manual
- Check Drive, Motor and
Wiring
1267 Indexing drum F-Stop Reason:
drive alarm no. - Sinamics S120 drive
##### U1161 Alarm
Remedy:
- Look-up Fault code in
SINAMICS List Manual
- Check Drive, Motor and
Wiring
1268 Indexing drum 1st F-Stop Reason:
axis error no. - First Simotion Axis U1161
##### Error
- Error caused drive to stop
Remedy:
- Look-up Fault code in
SIMOTION Manual
1269 Indexing drum 2nd F-Stop Reason:
axis error no. - Second Simotion Axis
##### U1161 Error
- Following Error
Remedy:
- Look-up Fault code in
SIMOTION Manual
1270 Indexing drum first F-Stop Reason:
following object - First Simotion Following
error no. ##### Axis U1161 Error
- Error caused drive to stop
Remedy:
- Look-up Fault code in
SIMOTION Manual
1271 Indexing drum F-Stop Reason:
second following - Second Simotion Following
object error no. Axis U1161 Error
##### - Following Error
Remedy:
- Look-up Fault code in
SIMOTION Manual

8-20 Zelos Operating Manual V1.0

8 - Troubleshooting
Error messages

Error Message Class Reason/ Remedy

No.
1272 Indexing drum F-Stop Reason:
reference sensor - U1161 Reference sensor
not found not found within specified
path length
Remedy:
- Check reference sensor -
B4102 and activation disk
- Check mechanics of
machine
- Check Input DI10 at D435
(-A2381) terminal X122:12
1273 Indexing drum F-Stop Reason:
motion timeout - U1161 Drive did not
respond to power on or
motion command
Remedy:
- Check for pending drive
alarms
- Check main supply and
infeed module
1274 Indexing drum F-Stop Reason:
torque limit - Servo motor run at torque
exceeded limit.
Remedy:
- Check mechanical system
for jam or excessive friction.
1275 Indexing drum not Info Reason:
referenced - Drive U1161 axis
coordinates not aligned
Remedy:
- Run reference function in
Setup Mode
- Start machine in Automatic
mode
1276 Indexing drum Info Reason:
referencing - Movement to find reference
position running
1277 Indexing drum Warning Remedy:
safety circuit test - Open and close safety
required enclosure (door)
- Press emergency stop
button and reset
1300 ZELOS cutting F-Stop Reason:
diameter not home - Cutting dia. axis not in
home position
Remedy:
- Reference axis
- Check sensor B4312

Operating Manual V1.0 Zelos 8-21

8 - Troubleshooting
Error messages

Error Message Class Reason/ Remedy

No.
1303 ZELOS cutting Warning Reason:
mandrel product - Product not loaded correct
dislocated at cutting station.
Remedy:
- Check alignment of rubber
roller.
- Check adjustment of
Product on position sensor
1304 ZELOS mandrel F-Stop Remedy:
breaker not ok - Check breaker 400V AC
distribution
- Check Breaker Q1371
1305 ZELOS mandrel F-Stop Remedy:
not in operation - Check ZELOS mandrel belt
- Check Proximity sensor
B4231
1306 ZELOS cutting F-Stop Reason:
overload - Mechanical jam or crash at
cutting diameter movement
Remedy:
- Check cutting station for
any crash
- Check sensor B4313
1307 ZELOS cutting F-Stop Reason:
length not home - Cutting length axis not in
home position
Remedy:
- Reference axis
- Check sensor B4311
1308 ZELOS grinding F-Stop --
timeout
1309 ZELOS cutting F-Stop
length wrong Remedy:
setting - Check cutting length
settings
1310 ZELOS cutting F-Stop
diameter wrong Remedy:
setting - Check cutting diameter
settings

8-22 Zelos Operating Manual V1.0

8 - Troubleshooting
Error messages

Error Message Class Reason/ Remedy

No.
1311 ZELOS knife R-Stop Reason:
revolver not - Knife revolver not in locked
engaged position.
Remedy:
- Rotate knife revolver
manual by 1 segment.
- Check knife revolver is
locked by cylinder -Y4322.
- Check cylinder position
feedback sensor -B4315
1312 ZELOS knife R-Stop Reason:
revolver - Knife revolver engage
disengage timeout cylinder not retracted.
Remedy:
- Check the locking cylinder
and solenoid -Y4322.
- Check the disengaged
feedback sensor -B4315.
1313 ZELOS knife R-Stop Reason:
revolver rotation - Knife revolver rotation
timeout reference sensor not found.
Remedy:
- Check the knife revolver
drive and motor -U3017, -
M3017.
- Check the reference
sensor -B4314.
1314 ZELOS knife R-Stop Reason:
revolver drive fault - ZELOS knife revolver drive
fault
Remedy:
- Check motor cable and its
wiring U3017
1315 ZELOS main F-Stop Reason:
cabinet: Mandrel - ZELOS mandrel drive
drive U1371 U1371 profinet offline
profinet fault Remedy:
- Check profinet connection
PN/IO- cables- connectors
1316 Cutting diameter F-Stop Reason:
drive fault no. - Sinamics S120 drive
##### U1171 Fault
Remedy:
- Look-up Fault code in
SINAMICS List Manual
- Check Drive, Motor and
Wiring

Operating Manual V1.0 Zelos 8-23

8 - Troubleshooting
Error messages

Error Message Class Reason/ Remedy

No.
1317 Cutting diameter F-Stop Reason:
drive alarm no. - Sinamics S120 drive
##### U1171 Alarm
Remedy:
- Look-up Fault code in
SINAMICS List Manual
- Check Drive, Motor and
Wiring
1318 Cutting diameter F-Stop Reason:
first axis error no. - First Simotion Axis U1171
##### Error
- Error caused drive to stop
Remedy:
- Look-up Fault code in
SIMOTION Manual
1319 Cutting diameter F-Stop Reason:
second axis error - Second Simotion Axis
no. ##### U1171 Error
- Following Error
Remedy:
- Look-up Fault code in
SIMOTION Manual
1322 Cutting diameter F-Stop Reason:
reference sensor - U1171 Reference sensor
not found not found within specified
path length
Remedy:
- Check reference sensor
B4312 and activation disk
- Check mechanics of
machine
- Check Input DI13 at D435
(A2381) terminal X132:10
1323 Cutting diameter F-Stop Reason:
motion timeout - U1171 Drive did not
respond to power on or
motion command
Remedy:
- Check for pending drive
alarms
- Check main supply and
infeed module
1324 Cutting diameter F-Stop Reason:
command error no. - U1171 Technology Object
##### command error
Remedy:
- Look-up Fault code in
SIMOTION Manual

8-24 Zelos Operating Manual V1.0

8 - Troubleshooting
Error messages

Error Message Class Reason/ Remedy

No.
1325 Cutting diameter Info Reason:
not referenced - Drive U1171 axis
coordinates not aligned
Remedy:
- Run reference function in
Setup Mode
- Start machine in Automatic
mode
1326 Cutting diameter is Info Reason:
referencing - Movement to find reference
position running
1327 Cutting diameter Warning Remedy:
test safety circuit - Open and close safety
required enclosure (door)
- Press emergency stop
button and reset
1330 Cutting diameter F-Stop Reason:
axis negative - Software limit at back
software limit reached or movement will
exceeded collide with limit:
Remedy:
- Check settings for cutting
diameter in Machine
Parameters.
1331 Cutting diameter F-Stop Reason:
axis positive - Software limit at front
software limit reached or movement will
exceeded collide with limit:
Remedy:
- Check settings for cutting
diameter in Machine
Parameters.
1332 Cutting length F-Stop Reason:
drive fault no. - Sinamics S120 drive
##### U1171 Fault
Remedy:
- Look-up Fault code in
SINAMICS List Manual
- Check Drive, Motor and
Wiring.
1333 Cutting length F-Stop Reason:
drive alarm no. - Sinamics S120 drive
##### U1171 Alarm
Remedy:
- Look-up Fault code in
SINAMICS List Manual
- Check Drive, Motor and
Wiring.

Operating Manual V1.0 Zelos 8-25

8 - Troubleshooting
Error messages

Error Message Class Reason/ Remedy

No.
1334 Cutting length first F-Stop Reason:
axis error no. - First Simotion Axis U1171
##### Error
- Error caused drive to stop
Remedy:
- Look-up Fault code in
SIMOTION Manual
1335 Cutting length F-Stop Reason:
second axis error - Second Simotion Axis
no. ##### U1171 Error
- Following Error
Remedy:
- Look-up Fault code in
SIMOTION Manual
1338 Cutting length F-Stop Reason:
reference sensor - U1171 Reference sensor
not found not found within specified
path length
Remedy:
- Check reference sensor
B4311 and activation disk
- Check mechanics of
machine
- Check Input DI11 at D435
(A2381) terminal X122:13
1339 Cutting length F-Stop Reason:
motion timeout - U1171 Drive did not
respond to power on or
motion command
Remedy:
- Check for pending drive
alarms
- Check main supply and
infeed module
1340 Cutting length F-Stop Reason:
command error no. - U1171 Technology Object
##### command error
Remedy:
- Look-up Fault code in
SIMOTION Manual
1341 Cutting length not Info Reason:
referenced - Drive U1171 axis
coordinates not aligned
Remedy:
- Run reference function in
Setup Mode
- Start machine in Automatic
mode

8-26 Zelos Operating Manual V1.0

8 - Troubleshooting
Error messages

Error Message Class Reason/ Remedy

No.
1342 Cutting length is Info Reason:
referencing - Movement to find reference
position running
1343 Cutting length test Warning Remedy:
safety circuit - Open and close safety
required enclosure (door)
- Press emergency stop
button and reset
1346 Cutting length axis F-Stop Reason:
negative software - Software limit at back
limit exceeded reached or movement will
collide with limit:
Remedy:
- Check settings for cutting
length in Machine
Parameters.
1347 Cutting length axis F-Stop Reason:
positive software - Software limit at front
limit exceeded reached or movement will
collide with limit:
Remedy:
- Check settings for cutting
length in Machine
Parameters.
1348 ZELOS Mandrel F-Stop Reason:
first drive fault no. - U1371 SINAMICS G120C
##### first drive Fault
- Fault caused drive to stop
Remedy:
- Look-up Fault code in
SINAMICS G120C Manual
- Check Drive, Motor and
Wiring
1349 ZELOS Mandrel F-Stop Reason:
second drive fault - U1371 SINAMICS G120C
no. ##### second drive Fault
- Following Fault
Remedy:
- Look-up Fault code in
SINAMICS G120C Manual
- Check Drive, Motor and
Wiring

Operating Manual V1.0 Zelos 8-27

8 - Troubleshooting
Error messages

Error Message Class Reason/ Remedy

No.
1350 ZELOS Mandrel R-Stop Reason:
first drive alarm no. - U1371 SINAMICS G120C
##### first drive Alarm
- Alarm caused drive to stop
Remedy:
- Look-up Alarm code in
SINAMICS G120C Manual
- Check Drive, Motor and
Wiring
1351 ZELOS Mandrel R-Stop Reason:
second drive alarm - U1371 SINAMICS G120C
no. ##### second drive Alarm
- Following Alarm
Remedy:
- Look-up Alarm code in
SINAMICS G120C Manual
- Check Drive, Motor and
Wiring
1352 ZELOS Mandrel R-Stop Reason:
motor over - Motor temperature too high
temperature Remedy:
- Check load of motor
- PTC motor cable
connection
1353 ZELOS Mandrel R-Stop Reason:
drive converter - Drive temperature too high
over temperature Remedy:
- Check motor load
- Check cabinet ventilator
1354 ZELOS Mandrel Warning Remedy:
test safety circuit - Press E-Stop and reset
required - Power off and power on
main cabinet
1355 ZELOS Mandrel R-Stop Reason:
operation timeout - Drive move command but
no rotation detected.
Remedy:
- Check motor and belt for
jam or high friction.
- Check inverter drive and
wiring.
1364 ZELOS electric R-Stop Reason:
box: mandrel - Speed monitoring module
speed monitoring error
load function error

8-28 Zelos Operating Manual V1.0

8 - Troubleshooting
Error messages

Error Message Class Reason/ Remedy

No.
1365 ZELOS electric R-Stop Reason:
box: mandrel - Speed monitoring module
speed monitoring error
parameter
assignment error
1366 ZELOS electric R-Stop Reason:
box: mandrel - Speed monitoring module
speed monitoring error
short circuit, wire Remedy:
break or over - Check cable and module
temperature A3572.1
- Check sensor -B4231
1367 ZELOS electric R-Stop Reason:
box: mandrel - Speed monitoring module
speed monitoring error
encoder supply
short circuit
1380 Cutting pressure F-Stop Reason:
roller drive fault no. - U1181 SINAMICS S120
##### first drive Fault
- Fault caused drive to stop
Remedy:
- Look-up Fault code in
SINAMICS S120 Manual
- Check Drive, Motor and
Wiring
1381 Cutting pressure F-Stop Reason:
roller drive alarm - U1181 SINAMICS S120
no. ##### second drive Fault
- Following Fault
Remedy:
- Look-up Fault code in
SINAMICS S120 Manual
- Check Drive, Motor and
Wiring
1382 Cutting pressure R-Stop Reason:
roller first axis error - U1181 SINAMICS S120
no. ##### first drive Alarm
- Alarm caused drive to stop
Remedy:
- Look-up Alarm code in
SINAMICS S120 Manual
- Check Drive, Motor and
Wiring

Operating Manual V1.0 Zelos 8-29

8 - Troubleshooting
Error messages

Error Message Class Reason/ Remedy

No.
1383 Cutting pressure R-Stop Reason:
roller second axis - U1181 SINAMICS S120
error no. ##### second drive Alarm
- Following Alarm
Remedy:
- Look-up Alarm code in
SINAMICS S120 Manual
- Check Drive, Motor and
Wiring
1384 Cutting pressure R-Stop Reason:
roller first following - Motor temperature too high
object error no. Remedy:
- Check load of motor
- PTC motor cable
connection
1385 Cutting pressure R-Stop Reason:
roller second - Drive temperature too high
following object Remedy:
error no. - Check motor load
- Check cabinet ventilator
1386 Cutting pressure Warning Remedy:
roller reference - Press E-Stop and reset
sensor not found - Power off and power on
main cabinet
1387 Cutting pressure R-Stop Reason:
roller motion - Drive move command but
timeout no rotation detected.
Remedy:
- Check motor and belt for
jam or high friction.
- Check inverter drive and
wiring.
1388 Cutting pressure F-Stop --
roller torque limit
exceeded
1389 Cutting pressure Info --
roller not
referenced
1390 Cutting pressure Info --
roller referencing
in process
1391 Cutting pressure Warning --
roller safety circuit
test required

8-30 Zelos Operating Manual V1.0

8 - Troubleshooting
Error messages

Error Message Class Reason/ Remedy

No.
1400 ZELOS main R-Stop Remedy:
cabinet: breaker - Check brush drive -U1381
brush 1 not ok and motor -M1381
- Check circuit breaker -
Q1381
1401 Brush 1 oscillator R-Stop Reason:
not engaged - Brush oscillate not engage
Remedy:
- Engage brush oscillate in
working position
- Check sensor B4332
1406 Dust separator R-Stop Remedy:
brush 1: suction air - Check exhaust piping.
flow not ok - Check flow sensor -B4337
and -K4337.
1407 Dust separator R-Stop Remedy:
brush 1: water level - Check level sensor setting
too low -B4383
- Check water supply.
- Check solenoid value.
1408 Dust separator Warning Remedy:
brush 1: water - Check water supply.
filling timeout - Check solenoid value.
1409 Brush 1 cleaning R-Stop Remedy:
engage timeout - Check air supply value -
Y4342
- Check proximity switch -
B4333
1410 Brush 1 cleaning R-Stop Remedy:
disengage timeout - Check air supply value -
Y4342
- Check proximity switch -
B4334
1412 Brush 1 oscillator R-Stop Remedy:
sync to turret time - Try to start machine again.
out - Try to Reference machine
again.
1415 ZELOS main Notification Reason:
cabinet: brush 1 - ZELOS brush drive -U1381
drive U1381 profinet offline
profinet fault Remedy:
- Check profinet connection
PN/IO- cables- connectors

Operating Manual V1.0 Zelos 8-31

8 - Troubleshooting
Error messages

Error Message Class Reason/ Remedy

No.
1416 Brush 1 first drive F-Stop Reason:
fault no. ##### - U1381 SINAMICS G120C
first drive Fault
- Fault caused drive to stop
Remedy:
- Look-up Fault code in
SINAMICS G120C Manual
- Check Drive, Motor and
Wiring
1417 Brush 1 second F-Stop Reason:
drive fault no. - U1381 SINAMICS G120C
##### second drive Fault
- Following Fault
Remedy:
- Look-up Fault code in
SINAMICS G120C Manual
- Check Drive, Motor and
Wiring
1418 Brush 1 first drive R-Stop Reason:
alarm no. ##### - U1381 SINAMICS G120C
first drive Alarm
- Alarm caused drive to stop
Remedy:
- Look-up Alarm code in
SINAMICS G120C Manual
- Check Drive, Motor and
Wiring
1419 Brush 1 second R-Stop Reason:
drive alarm no. - U1381 SINAMICS G120C
##### second drive Alarm
- Following Alarm
Remedy:
- Look-up Alarm code in
SINAMICS G120C Manual
- Check Drive, Motor and
Wiring
1420 Brush 1 motor over R-Stop Reason:
temperature - M1381 motor over-heated
Remedy:
- Check motor load
- Check motor cooling fan
1421 Brush 1 drive R-Stop Reason:
converter over - U1381 inverter over-
temperature heated
Remedy:
- Check inverter cooling fan

8-32 Zelos Operating Manual V1.0

8 - Troubleshooting
Error messages

Error Message Class Reason/ Remedy

No.
1422 Brush 1 safety Warning Remedy:
circuit test required - Open and close safety
enclosure (door)
- Press emergency stop
button and reset
1423 Brush 1 operation R-Stop Reason:
timeout - M1381 no rotation detected
Remedy
- Check motor can freely
rotate
1432 Brush 1 oscillator F-Stop Reason:
drive fault no. - Sinamics S120 drive
##### U1191 Fault
Remedy:
- Look-up Fault code in
SINAMICS List Manual
- Check Drive, Motor and
Wiring
1433 Brush 1 oscillator F-Stop Reason:
drive alarm no. - Sinamics S120 drive
##### U1191 Alarm
Remedy:
- Look-up Fault code in
SINAMICS List Manual
- Check Drive, Motor and
Wiring
1434 Brush 1 oscillator F-Stop Reason:
1st axis error no. - First Simotion Axis U1191
##### Error
- Error caused drive to stop
Remedy:
- Look-up Fault code in
SIMOTION Manual
1435 Brush 1 oscillator F-Stop Reason:
2nd axis error no. - Second Simotion Axis
##### U1191 Error
- Following Error
Remedy:
- Look-up Fault code in
SIMOTION Manual
1436 Brush 1 oscillator F-Stop Reason:
1st following object - First Simotion Following
error no. ##### Axis U1191 Error
- Error caused drive to stop
Remedy:
- Look-up Fault code in
SIMOTION Manual

Operating Manual V1.0 Zelos 8-33

8 - Troubleshooting
Error messages

Error Message Class Reason/ Remedy

No.
1437 Brush 1 oscillator F-Stop Reason:
2nd following - Second Simotion Following
object error no. Axis U1191 Error
##### - Following Error
Remedy:
- Look-up Fault code in
SIMOTION Manual
1438 Brush 1 oscillator R-Stop Reason:
reference - U1191 Reference sensor
proximity not found not found within specified
path length
Remedy:
- Check reference sensor -
B4331 and activation disk
- Check mechanics of
machine
- Check Input DI10 at CU320
(-A2383) terminal X122:12
1439 Brush 1 oscillator R-Stop Reason:
motion timeout - U1191 Drive did not
respond to power on or
motion command
Remedy:
- Check for pending drive
alarms
- Check main supply and
infeed module
1440 Brush 1 oscillator F-Stop Reason:
torque limit - Servo motor run at torque
exceeded limit.
Remedy:
- Check mechanical system
for jam or excessive friction.
1441 Brush 1 oscillator Info Reason:
not referenced - Drive U1191 axis
coordinates not aligned
Remedy:
- Run reference function in
Setup Mode
- Start machine in Automatic
mode
1442 Brush 1 oscillator Info Reason:
referencing - Movement to find reference
position running

8-34 Zelos Operating Manual V1.0

8 - Troubleshooting
Error messages

Error Message Class Reason/ Remedy

No.
1443 Brush 1 oscillator Warning Remedy:
safety circuit test - Open and close safety
required enclosure (door)
- Press emergency stop
button and reset
1448 Brush 1 pressure F-Stop Reason:
roller drive fault no. - Sinamics S120 drive
##### U1201 Fault
Remedy:
- Look-up Fault code in
SINAMICS List Manual
- Check Drive, Motor and
Wiring
1449 Brush 1 pressure F-Stop Reason:
roller drivev alarm - Sinamics S120 drive
no. ##### U1201 Alarm
Remedy:
- Look-up Fault code in
SINAMICS List Manual
- Check Drive, Motor and
Wiring
1450 Brush 1 pressure F-Stop Reason:
roller first axis error - First Simotion Axis U1120
no. ##### Error
- Error caused drive to stop
Remedy:
- Look-up Fault code in
SIMOTION Manual
1451 Brush 1 pressure F-Stop Reason:
roller second axis - Second Simotion Axis
error no. ##### U1201 Error
- Following Error
Remedy:
- Look-up Fault code in
SIMOTION Manual
1452 Brush 1 pressure Info --
roller first following
object error no.
1453 Brush 1 pressure Info --
roller second
following object
error no.
1454 Brush 1 pressure R-Stop Reason:
roller reference - U1191 Reference sensor
sensor not found not found within specified
path length
Remedy:

Operating Manual V1.0 Zelos 8-35

8 - Troubleshooting
Error messages

Error Message Class Reason/ Remedy

No.
1455 Brush 1 pressure R-Stop Reason:
roller motion - U1201 Drive did not
timeout respond to power on or
motion command
Remedy:
- Check for pending drive
alarms
- Check main supply and
infeed module
1456 Brush 1 pressure F-Stop Reason:
roller torque limit - Servo motor run at torque
exceeded limit.
Remedy:
- Check mechanical system
for jam or excessive friction.
1457 Brush 1 pressure Info Reason:
roller not - Drive U1201 axis
referenced coordinates not aligned
Remedy:
- Run reference function in
Setup Mode
- Start machine in Automatic
mode
1458 Brush 1 pressure Info Reason:
roller referencing - Movement to find reference
position running
1459 Brush 1 pressure Warning Remedy:
safety circuit test - Open and close safety
required enclosure (door)
- Press emergency stop
button and reset
1500 ZELOS main R-Stop Remedy:
cabinet: breaker - Check brush drive -U1391
brush 2 not ok and motor -M1391
- Check circuit breaker -
Q1391
1501 Brush 2 oscillator R-Stop Reason:
not engaged - Brush oscillate not engage
Remedy:
- Engage brush oscillate in
working position
- Check sensor B4352
1506 Dust separator R-Stop Remedy:
brush 2: suction air - Check exhaust piping.
flow not ok - Check flow sensor -B4357
and -K4357.

8-36 Zelos Operating Manual V1.0

8 - Troubleshooting
Error messages

Error Message Class Reason/ Remedy

No.
1507 Dust separator R-Stop Remedy:
brush 2: water level - Check level sensor setting
too low -B4393
- Check water supply.
- Check solenoid value.
1508 Dust separator R-Stop Remedy:
brush 2: water - Check water supply.
filling timeout - Check solenoid value.
1509 Brush 2 cleaning R-Stop Remedy:
engage timeout - Check air supply value -
Y4362
- Check proximity switch -
B4353
1510 Brush 2 cleaning R-Stop Remedy:
disengage timeout - Check air supply value -
Y4362
- Check proximity switch -
B4354
1512 Brush 2 oscillator R-Stop Remedy:
sync time out - Try to start machine again.
- Try to Reference machine
again.
1515 ZELOS main Info Reason:
cabinet: brush 2 - ZELOS brush drive -U1391
drive U1391 profinet offline
profinet fault Remedy:
- Check profinet connection
PN/IO- cables- connectors
1516 Brush 2 first drive F-Stop Reason:
fault no. ##### - U1391 SINAMICS G120C
first drive Fault
- Fault caused drive to stop
Remedy:
- Look-up Fault code in
SINAMICS G120C Manual
- Check Drive, Motor and
Wiring
1517 Brush 2 second F-Stop Reason:
drive fault no. - U1391 SINAMICS G120C
##### second drive Fault
- Following Fault
Remedy:
- Look-up Fault code in
SINAMICS G120C Manual
- Check Drive, Motor and
Wiring

Operating Manual V1.0 Zelos 8-37

8 - Troubleshooting
Error messages

Error Message Class Reason/ Remedy

No.
1518 Brush 2 first drive R-Stop Reason:
alarm no. ##### - U1391 SINAMICS G120C
first drive Alarm
- Alarm caused drive to stop
Remedy:
- Look-up Alarm code in
SINAMICS G120C Manual
- Check Drive, Motor and
Wiring
1519 Brush 2 second R-Stop Reason:
drive alarm no. - U1391 SINAMICS G120C
##### second drive Alarm
- Following Alarm
Remedy:
- Look-up Alarm code in
SINAMICS G120C Manual
- Check Drive, Motor and
Wiring
1520 Brush 2 motor over R-Stop Reason:
temperature - M1391 motor over-heated
Remedy:
- Check motor load
- Check motor cooling fan
1521 Brush 2 drive R-Stop Reason:
converter over - U1391 inverter over-
temperature heated
Remedy:
- Check inverter cooling fan
1522 Brush 2 test safety Warning Remedy:
circuit required - Open and close safety
enclosure (door)
- Press emergency stop
button and reset
1523 Brush 2 operation R-Stop Reason:
timeout - M1391 no rotation detected
Remedy:
- Check motor can freely
rotate
1532 Brush 2 oscillator F-Stop Reason:
drive fault no. - Sinamics S120 drive
##### U1191 Fault
Remedy:
- Look-up Fault code in
SINAMICS List Manual
- Check Drive, Motor and
Wiring

8-38 Zelos Operating Manual V1.0

8 - Troubleshooting
Error messages

Error Message Class Reason/ Remedy

No.
1533 Brush 2 oscillator F-Stop Reason:
drive alarm no. - Sinamics S120 drive
##### U1191 Alarm
Remedy:
- Look-up Fault code in
SINAMICS List Manual
- Check Drive, Motor and
Wiring
1534 Brush 2 oscillator F-Stop Reason:
1st axis error no. - First Simotion Axis U1191
##### Error
- Error caused drive to stop
Remedy:
- Look-up Fault code in
SIMOTION Manual
1535 Brush 2 oscillator F-Stop Reason:
2nd axis error no. - Second Simotion Axis
##### U1191 Error
- Following Error
Remedy:
- Look-up Fault code in
SIMOTION Manual
1536 Brush 2 oscillator F-Stop Reason:
1st following object - First Simotion Following
error no. ##### Axis U1191 Error
- Error caused drive to stop
Remedy:
- Look-up Fault code in
SIMOTION Manual
1537 Brush 2 oscillator F-Stop Reason:
2nd following - Second Simotion Following
object error no. Axis U1191 Error
##### - Following Error
Remedy:
- Look-up Fault code in
SIMOTION Manual
1538 Brush 2 oscillator R-Stop Reason:
reference - U1191 Reference sensor
proximity not found not found within specified
path length
Remedy:
- Check reference sensor -
B4351 and activation disk
- Check mechanics of
machine
- Check Input DI11 at CU320
(-A2383) terminal X122:13

Operating Manual V1.0 Zelos 8-39

8 - Troubleshooting
Error messages

Error Message Class Reason/ Remedy

No.
1539 Brush 2 oscillator R-Stop Reason:
motion timeout - U1191 Drive did not
respond to power on or
motion command
Remedy:
- Check for pending drive
alarms
- Check main supply and
infeed module
1540 Brush 2 oscillator F-Stop Reason:
torque limit - Servo motor run at torque
exceeded limit.
Remedy:
- Check mechanical system
for jam or excessive friction.
1541 Brush 2 oscillator Info Reason:
not referenced - Drive U1191 axis
coordinates not aligned
Remedy:
- Run reference function in
Setup Mode
- Start machine in Automatic
mode
1542 Brush 2 oscillator Info Reason:
referencing - Movement to find reference
position running
1543 Brush 2 oscillator Warning Remedy:
safety circuit test - Open and close safety
required enclosure (door)
- Press emergency stop
button and reset
1548 Brush 2 pressure F-Stop Reason:
roller drive fault no. - Sinamics S120 drive
##### U1201 Fault
Remedy:
- Look-up Fault code in
SINAMICS List Manual
- Check Drive, Motor and
Wiring
1549 Brush 2 pressure F-Stop Reason:
roller drivev alarm - Sinamics S120 drive
no. ##### U1201 Alarm
Remedy:
- Look-up Fault code in
SINAMICS List Manual
- Check Drive, Motor and
Wiring

8-40 Zelos Operating Manual V1.0

8 - Troubleshooting
Error messages

Error Message Class Reason/ Remedy

No.
1550 Brush 2 pressure F-Stop Reason:
roller first axis error - First Simotion Axis U1201
no. ##### Error
- Error caused drive to stop
Remedy:
- Look-up Fault code in
SIMOTION Manual
1551 Brush 2 pressure F-Stop Reason:
roller second axis - Second Simotion Axis
error no. ##### U1201 Error
- Following Error
Remedy:
- Look-up Fault code in
SIMOTION Manual
1552 Brush 2 pressure Info --
roller first following
object error no.
1553 Brush 2 pressure Info --
roller second
following object
error no.
1554 Brush 2 pressure R-Stop Reason:
roller refernce - U1201 Reference sensor
sensor not found not found within specified
path length
Remedy:
1555 Brush 2 pressure R-Stop Reason:
roller motoin - U1201 Drive did not
timeout respond to power on or
motion command
Remedy:
- Check for pending drive
alarms
- Check main supply and
infeed module
1556 Brush 2 pressure F-Stop Reason:
roller torque limit - Servo motor run at torque
exceeded limit.
Remedy:
- Check mechanical system
for jam or excessive friction.

Operating Manual V1.0 Zelos 8-41

8 - Troubleshooting
Error messages

Error Message Class Reason/ Remedy

No.
1557 Brush 2 pressure Info Reason:
roller not - Drive U1201 axis
referenced coordinates not aligned
Remedy:
- Run reference function in
Setup Mode
- Start machine in Automatic
mode
1558 Brush 2 pressure Info Reason:
roller referencing - Movement to find reference
position running
1559 Brush 2 pressure Warning Remedy:
safety circuit test - Open and close safety
required enclosure (door)
- Press emergency stop
button and reset
1700 Outfeed chain F-Stop Reason:
dancer out of limit - Zelos outfeed chain
tensioner out of limit
Remedy:
- Check chain for blockage,
jam or elongation
- Check tensioner
arrangement
- Check sensor -B4516
1701 Outfeed drum F-Stop Reason:
overload - Zelos outfeed discharge
drum overload
Remedy:
- Check discharge drum for
blockage, jam or elongation
- Check sensor -B5645
1704 Outfeed chain F-Stop Reason:
product return - Product return from outfeed
drum
Remedy:
- Check discharge drum.
- Check sensor -B5642
1705 Rejection in F-Stop Reason:
manual mode - Manual reject function is
switch on
1706 Auto rejection Warning Reason:
switched off - Auto reject function is
switch off
1708 Product on washer F-Stop --
transfer - no
manual mode

8-42 Zelos Operating Manual V1.0

8 - Troubleshooting
Error messages

Error Message Class Reason/ Remedy

No.
1711 Reject air blow R-Stop --
settings error
1712 -- F-Stop --
1713 -- F-Stop --
1714 Washer follow R-Stop --
Zelos timeout
1715 Zelos outfeed Warning Reason:
chain lubrication - Lubrication level empty
empty Remedy:
- Check lubrication level
- Check level sensor S4525
1716 ZELOS chain F-Stop Reason:
drive: drive fault - Sinamics S120 drive
no. ##### U1161 Fault.
Remedy:
- Look-up Fault code in
SINAMICS List Manual.
- Check Drive -U1201.
- Check Motor -M1205.
- Check Wiring.
1717 ZELOS chain F-Stop Reason:
drive: drive alarm - Sinamics S120 drive
no. ##### U1161 Alarm.
Remedy:
- Look-up Alarm code in
SINAMICS List Manual.
- Check Drive -U1201.
- Check Motor -M1205.
- Check Wiring.
1718 ZELOS chain F-Stop Reason:
drive: 1st axis error - First Simotion Axis U1161
no. <field ref="1" /> Error.
- Error caused drive to stop.
Remedy:
- Look-up Fault code in
SIMOTION Manual.
1719 ZELOS chain F-Stop Reason:
drive: 2nd axis - Second Simotion Axis
error no. <field U1161 Error.
ref="1" /> - Following Error.
Remedy:
- Look-up Fault code in
SIMOTION Manual.

Operating Manual V1.0 Zelos 8-43

8 - Troubleshooting
Error messages

Error Message Class Reason/ Remedy

No.
1720 ZELOS chain F-Stop Reason:
drive: 1st following - First Simotion Following
object error no. Axis U1161 Error.
<field ref="1" /> - Error caused drive to stop.
Remedy:
- Look-up Fault code in
SIMOTION Manual.
1721 ZELOS chain F-Stop Reason:
drive: 2nd - Second Simotion Following
following object Axis U1161 Error.
error no. <field - Following Error.
ref="1" /> Remedy:
- Look-up Fault code in
SIMOTION Manual.
1722 ZELOS chain R-Stop Reason:
drive: reference - Can't detect reference
sensor not found sensor of infeed drive.
Remedy:
- Check for mechanic jam of
machine.
- Check proximity switch -
B4501.
- Check Input DI14 at
terminal 12 of X132 at D435.
1723 ZELOS chain F-Stop --
drive: motion
timeout
1724 ZELOS chain drive F-Stop Reason:
torque limit - Drive torque higher than
exceeded nominal for extended time.
Remedy:
- Check mechanic system
for high friction and
blockage.
- Check lubrication.
1725 ZELOS chain drive Info Reason:
not referenced - Start balancing by
reference button.
- Start balancing by selecting
machine Inching or
Continue mode.
1726 ZELOS Info Reason:
referencing in - Chain balancing in
process process.

8-44 Zelos Operating Manual V1.0

8 - Troubleshooting
Error messages

Error Message Class Reason/ Remedy

No.
1727 ZELOS chain drive Warning Reason:
safety circuit test - Safety system requires
required testing of the functions.
Remedy:
- Stop the machine, open the
door and close it again OR
- Stop the machine, push
emergency stop and reset.
10000 New recipe Notification --
created
10001 Recipe open for Notification --
editing : #####
10002 Recipe loaded to Notification --
machine
10003 Successfully save Notification --
the selected recipe
10004 Successfully Notification --
delete the selected
recipe
10005 Successfully Notification --
update recipe
value
10006 No recipe opened Notification --
10012 Successfully Notification --
download machine
parameter
10013 Successfully Notification --
saved machine
parameter
10015 Successfully Notification --
uploaded machine
parameter
10022 Successfully Notification --
downloaded
system configure
10023 Successfully Notification --
saved system
configure

Operating Manual V1.0 Zelos 8-45

8 - Troubleshooting
Error messages

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8-46 Zelos Operating Manual V1.0

9 - Disposal of the machine

9 Disposal of the machine

After decommissioning at the end of its service life, the equipment must be
disposed off according to the local environmental laws and regulations.
PackSys Global recommends leaving the disposal to a local disposal
company authorised to provide the necessary certificates verifying proper
disposal.

Operating Manual V1.0 Zelos 9-1

9 - Disposal of the machine

This page is intentionally kept blank

9-2 Zelos Operating Manual V1.0