Operating Manual - Feeder

WALTEC
Operating Manual
Electronic Control
Electronic Feeder TSE
WALTEC Maschinen GmbH, Kronacher Str. 2a, D-96352 Wilhelmsthal, 07/2015
Operating Manual - Electronic Control Feeder and Shears,z-e.doc
WALTEC
Notes to the conformity declaration based on the regulation

of the advisory board, to adapt the legal regulations of the
members of the states in regards to the electro-magnetic
compatibility (2004/108/EG)
The standard DIN EN 60439 Part1 Section 7.10 was used to evaluate a product in
regards to its electro-magnetic compatibility. Proves, which confirm that the abovementioned protective requirements are available for self-operating electronics built into
production equipment.
Required protective measures have been implemented into the product, which is part of
a system, for electronics, which is not built into the self-operating production equipment,
and has been assembled and installed by personnel that are knowledgeable in the field
of electro-magnetic compatibility. Thereby, the installation and assembly instructions
published by the manufacturer of the production equipment are observed, so that a
perfect operation of the system can be guaranteed.
The system complies with the requirements of the standards DIN EN 61000-6-4 and
DIN EN 61000-6-2.
This means that the system is designed for an industrial environment.
Note: The operating instruction manual is valid for several machine types and
configurations. Sections that relate to modules and/or devices, which are
not contained in the extend of the delivery, become irrelevant.
Note: We reserve the right to make changes based on technical advancement.
WALTEC
Maschinen GmbH
Kronacher Str. 2a
D-96352 Wilhelmsthal/Steinberg
Telefon: +49 (0)9260 99 01-0

Fax:+49 (0)9260 99 01-99
Email: info@waltec.de
Online: www.waltec.de
WALTEC
TABLE OF CONTENTS
1
FUNDAMENTAL SAFETY INSTRUCTIONS
1.1
Warnings and symbols
1.2
Basic operation and designated use of the machine/plant
1.3
Organisational measures
1.4
Selection and qualification of personnel - Basic responsibilities
10
1.5 Safety instructions governing specific operational phases

11
1.5.1 Standard operation
11
1.5.2 Special work in conjunction with utilisation of the machine/plant and maintenance and repairs
during operation; disposal of parts and consumables
12
1.6 Warning of special dangers
1.6.1 Electric energy
1.6.2 Gas, dust, steam and smoke
1.6.3 Hydraulic and pneumatic equipment
1.6.4 Noise
1.6.5 Oil, grease and other chemical substances
1.6.6 High temperature
14
14
15
15
15
16
16
1.7
Mobile machinery and equipment
16
ELECTRONIC LOGIC CONTROLLER
18
STRUCTURE OF CONTROL CABINET
18
DESCRIPTION OF THE FUNCTIONS IN THE CONTROL CABINET
19
4.1 Screen and keyboard

4.1.1 Description of the screen
4.1.2 Function Description
4.1.3 Screen Description
4.1.3.1
Screen Description: BASIC MASK
4.1.3.2
Screen Description: MASTER AXIS
4.1.3.3
Screen Description: CURVE MANAGEMENT
4.1.3.4
Screen Description: PLUNGER CURVE
4.1.3.5
Screen Description: PLUNGER CURVE POSITION + SPEED
4.1.3.6
Screen Description: PLUNGER MANUAL
4.1.3.7
Screen Description: PLUNGER (Assembling / Tempering)
4.1.3.8
Screen Description: SHEARS
4.1.3.9
Screen Description: SHEARS SPRAYING
4.1.3.10 Screen Description: GOB CHUTE / ADDITIONAL FUNCTIONS
4.1.3.11 Screen Description: SERVICE MASK
4.1.3.12 Screen Description: STATUS PROFIBUS
4.1.3.13 Screen Description: MACHINE DATA MC
4.1.3.14 Screen Description: LIMITATIONS
4.1.3.15 Screen Description: LUBRICATION
4.1.3.16 Screen Description: DIAGNOSIS MICROMASTER
4.1.3.17 Screen Description: STATUS SINAMICS
20
20
20
20
21
23
25
27
30
31
34
36
38
39
40
42
43
44
46
47
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4.1.3.18
4.1.3.19
4.1.3.20
4.1.3.21
4.1.3.22
4.1.3.23
4.1.3.24
4.1.3.25
4.1.3.26
4.1.3.27
4.1.3.28
4.1.3.29
4.1.3.30
4.1.3.31
4.1.3.32
Screen Description: STATUS CU320

Screen Description: STATUS INFEED
Screen Description: STATUS CPU
Screen Description: STATUS DIGITAL OUTPUTS / INPUTS
Screen Description: UPS STATUS
Screen Description: STATUS/CONTROL
Screen Description: PASSWORD LIST
Screen Description: DATE / TIME
Screen Description: Message display
Screen Description: Message archive
Screen Description: CPU diagnosis cache
Screen Description: Change log
Screen Description: Data Record Processing
Screen Description: Program information
Screen Description: Faults of electrical axis
51
52
53
54
55
56
57
58
59
60
61
62
63
66
67
SWITCHING MACHINE ON AND MANUAL OPERATION
68
INITIAL POSITION OF THE MACHINE AND AUTOMATIC OPERATION
69
6.1
Initial position
69
6.2
Engagement of automatic mode
69
6.3
Settings in automatic mode
69
6.4
Shutting off the machine
69
MALFUNCTION IN AUTOMATIC MODE AND EMERGENCY-OFF
70
MALFUNCTIONS AND THEIR RECTIFICATION S7-300
71
8.1
Overall Reset of the control S7-300
71
ADJUSTMENTS WHEN CHANGING AN AXES DRIVE
72
9.1
Necessity for Locating the Reference Point
72
9.2
Locating the Machine Reference Point
72
9.3
Calculating the Reference Point Displacement
73
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Foreword to the operating instructions

These operating instructions are designed to familiarise the user with the
machine/plant and its designated use.
The instruction manual contains important information on how to operate the
machine/plant safely, properly and most efficiently. Observing these instructions
helps to avoid danger, to reduce repair costs and downtimes and to increase the
reliability and life of the machine/plant.
The instruction manual is to be supplemented by the respective national rules
and regulations for accident prevention and environmental protection.
The operating instructions must always be available wherever the machine/plant
is in use.
These operating instructions must be read and applied by any person in charge
of carrying out work with and on the machine/plant, such as
operation including setting up, troubleshooting in the course of work, evacuation
of production waste, care and disposal of fuels and consumables.
maintenance (servicing, inspection, repair) and/or
transport
In addition to the operating instructions and to the mandatory rules and
regulations for accident prevention and environmental protection in the country
and place of use of the machine/plant, the generally recognised technical rules
for safe and proper working must also be observed.
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Fundamental safety instructions
1.1 Warnings and symbols

The following signs and designations are used in the manual to designate
instructions of particular importance.
Reference (refers to special information on how to use the

machine/plant most efficiently)
Attention (refers to special information and/or orders and prohibitions

directed towards preventing damage)
Danger
(refers to orders and prohibitions designed prevent injury or
extensive damage)
1.2 Basic operation and designated use of the machine/plant

1.2.1
The machine/plant has been built in accordance with state-of-the-art standards
and the recognised safety rules. Nevertheless, its use may constitute a risk to life
and limb of the user or of third parties, or cause damage to the machine and to
other material property.
1.2.2
The machine/plant must only be used in technically perfect condition in
accordance with its designated use and the instructions set out in the operating
manual, and only by safety-conscious persons who are fully aware of the risks
involved in operating the machine/plant. Any functional disorders, especially
those affecting the safety of the machine/plant, should therefore be rectified
immediately.
1.2.3
The machine/plant is designed exclusively for the production of hollow glass
articles. Using the machine/plant for purposes other than those mentioned above
(such as for spining or to transporting other materials except technical usable
kinds of glass) is considered contrary to its designated use. The
manufacturer/supplier cannot be held liable for any damage resulting from such
use. The risk of such misuse lies entirely with the user. Operating the machine
within the limits of its designated use also involves observing the instructions set
out in the operating manual and complying with the inspection and maintenance
directives.
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1.3 Organisational measures

1.3.1
The operating instructions must always be at hand at the place of use of the
machine/plant, e. g. by stowing them in the tool compartment or tool-box
provided for such purpose.
1.3.2
In addition to the operating instructions, observe and instruct the user in all other
generally applicable legal and other mandatory regulations relevant to accident
prevention and environmental protection.
These compulsory regulations may also deal with the handling of hazardous
substances, issuing and/or wearing of personal protective equipment, or traffic
regulations.
1.3.3
The operating instructions must be supplemented by instructions covering the
duties involved in supervising and notifying special organisational features, such
as job organisation, working sequences or the personnel entrusted with the work.
1.3.4
Personnel entrusted with work on the machine must have read the operating
instructions and in particular the chapter on safety before beginning work.
Reading the instructions after work has begun is too late. This applies especially
to persons working only occasionally on the machine, e. g. during setting up or
maintenance.
1.3.5
Check - at least from time to time - whether the personnel is carrying out the work
in compliance with the operating instructions and paying attention to risks and
safety factors.
1.3.6
For reasons of security, long hair must be tied back or otherwise secured,
garments must be close-fitting and no jewellery - such as rings - may be worn.
Injury may result from being caught up in the machinery or from rings catching on
moving parts.
1.3.7
Use protective equipment wherever required by the circumstances or by law.
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1.3.8
Observe all safety instructions and warnings attached to the machine/plant.
1.3.9
See to it that safety instructions and warnings attached to the machine are
always complete and perfectly legible.
1.3.10
In the event of safety-relevant modifications or changes in the behaviour of the
machine/plant during operation, stop the machine/plant immediately and report
the malfunction to the competent authority/ person.
1.3.11
Never make any modifications, additions or conversions which might affect safety
without the suppliers approval. This also applies to the installation and
adjustment of safety devices and valves as well as to welding work on loadbearing elements.
1.3.12
Spare parts must comply with the technical requirements specified by the
manufacturer. Spare parts from original equipment manufacturers can be relied
to do so.
1.3.13
Never modify the software of programmable control systems.
1.3.14
Replace hydraulic hoses within stipulated and appropriate intervals even if no
safety-relevant defects have been detected.
1.3.15
Adhere to prescribed intervals or those specified in the operating instructions for
routine checks and inspections.
1.3.16
For the execution of maintenance work, tools and workshop equipment adapted
to the task on hand are absolutely indispensable.
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1.3.17
The personnel must be familiar with the location and operation of fire
extinguishers.
1.3.18
Observe all fire-warning and fire-fighting procedures.
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1.4 Selection and qualification of personnel - Basic responsibilities

1.4.1
Any work on and with the machine/plant must be executed by reliable personnel
only. Statutory minimum age limits must be observed.
1.4.2
Employ only trained or instructed staff and set out clearly the individual
responsibilities of the personnel for operation, set-up, maintenance and repair.
1.4.3
Make sure that only authorised personnel works on or with the machine.
1.4.4
Define the machine operators responsibilities - also with regard to observing
traffic regulations - giving the operator the authority to refuse instructions by third
parties that are contrary to safety.
1.4.5
Do not allow persons to be trained or instructed or persons taking part in a
general training course to work on or with the machine/plant without being
permanently supervised by an experienced person.
1.4.6
Work on the electrical system and equipment of the machine/plant must be
carried out only by a skilled electrician or by instructed persons under the
supervision and guidance of a skilled electrician and in accordance with electrical
engineering rules and regulations.
1.4.7
Work on gas-fuelled equipment (gas consumers) may be carried out by specially
trained personnel only.
1.4.8
Work on the hydraulic system must be carried out only by personnel with special
knowledge and experience of hydraulic equipment.
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1.5 Safety instructions governing specific operational phases

1.5.1
Standard operation
1.5.1.1
Avoid any operational mode that might be prejudicial to safety, and don't
manipulate running machine.
1.5.1.2
Take the necessary precautions to ensure that the machine is used only when in
a safe and reliable state.
Operate the machine only if all protective and safety-oriented devices, such as
removable safety devices, emergency shut-off equipment, sound-proofing
elements and exhausters, are in place and fully functional.
1.5.1.3
Check the machine/plant at least once per working shift for obvious damage and
defects. Report any changes (incl. changes in the machines working behaviour)
to the competent organisation/person immediately. If necessary, stop the
machine immediately and lock it.
1.5.1.4
In the event of malfunctions, stop the machine/plant immediately and lock it.
Have any defects rectified immediately.
1.5.1.5
During start-up and shut-down procedures always watch the indicators in
accordance with the operating instructions.
1.5.1.6
Before starting up or setting the machine/plant in motion, make sure that nobody
is at risk.
1.5.1.7
Never switch off or remove suction and ventilation devices when the machine is
in operation.
1.5.1.8
Never handle glass or broken glass except with personal protective gear or
appropriate aids. (Risk of injury).
1.5.1.9
Handle glass with cracks or inclusions with special care. Risk of injury on
breakage.
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1.5.2
Special work in conjunction with utilisation of the machine/plant and
maintenance and repairs during operation; disposal of parts and consumables
1.5.2.1
Observe the adjusting, maintenance and inspection activities and intervals set
out in the operating instructions, including information on the replacement of
parts and equipment. These activities may be executed by skilled personnel only.
1.5.2.2
Brief operating personnel before beginning special operations and maintenance
work, and appoint a person to supervise the activities.
1.5.2.3
In any work concerning the operation, conversion or adjustment of the machine
and its safety- oriented devices or any work related to maintenance, inspection
and repair, always observe the start-up and shut-down procedures set out in the
operating instructions and the information on maintenance work.
1.5.2.4
Ensure that the maintenance area is adequately secured.
1.5.2.5
If the machine/plant is completely shut down for maintenance and repair work, it
must be secured against inadvertent starting by:
locking the principal control elements and removing the ignition key and/or
attaching a warning sign to the main switch.
1.5.2.6
To avoid the risk of accidents, individual parts and large assemblies being moved
for replacement purposes should be carefully attached to lifting tackle and
secured. Use only suitable and technically perfect lifting gear and suspension
systems with adequate lifting capacity. Never work or stand under suspended
loads.
1.5.2.7
The fastening of loads and the instructing of crane operators should be entrusted
to experienced persons only. The marshaller giving the instructions must be
within sight or sound of the operator.
1.5.2.8
For carrying out overhead assembly work always use specially designed or
otherwise safety-oriented ladders and working platforms. Never use machine
parts as a climbing aid. Wear a safety harness when carrying out maintenance
work at greater heights.
Keep all handles, steps, handrails, platforms, landings and ladders free from dirt,
oil and other lubricants!
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1.5.2.9
Clean the machine, especially connections and threaded unions, of any traces of
oil, fuel or preservatives before carrying out maintenance/repair. Never use
aggressive detergents. Use lint-free cleaning rags.
1.5.2.10
Before cleaning the machine with water, steam jet (high-pressure cleaning) or
detergents, cover or tape up all openings which - for safety and functional
reasons - must be protected against water, steam or detergent penetration.
Special care must be taken with electric motors and switchgear cabinets.
1.5.2.11
After cleaning, remove all covers and tapes applied for that purpose.
1.5.2.12
After cleaning, examine all fuel, lubricant and hydraulic fluid lines for leaks, loose
connections, chafe marks and damage. Any defects found must be rectified
without delay.
1.5.2.13
Always tighten any screwed connections that have been loosened during
maintenance and repair.
1.5.2.14
Any safety devices removed for set-up, maintenance or repair purposes must be
refitted and checked immediately upon completion of the maintenance and repair
work.
1.5.2.15
Ensure that all consumables and replaced parts are disposed of safely and with
minimum environmental impact.
1.5.2.16
For welding works at the machine/plant fasten ground cable of welding
apparatus directly to the part to be welded and shut off main switch of
machine/plant in each case. Otherwise electronic modules can be damaged. The
plant is earthed with big cross section cables and connected to all machine parts.
Connection to earth must be established for all welding works as long as the
machine part is connected to the control cabinet with any cable.
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1.6 Warning of special dangers

1.6.1
Electric energy
1.6.1.1
Use only original fuses with the specified current rating. Switch off the
machine/plant immediately if trouble occurs in the electrical system.
1.6.1.2
Work on the electrical system or equipment may only be carried out by a skilled
electrician himself or by specially instructed personnel under the control and
supervision of such electrician and in accordance with the applicable electrical
engineering rules.
1.6.1.3
If provided for in the regulations, the power supply to parts of machines and
plants, on which inspection, maintenance and repair work is to be carried out
must be cut off. Before starting any work, check the de-energised parts for
presence of power and ground or short-circuit them in addition to insulating
adjacent live parts and elements.
1.6.1.4
The electrical equipment of machines/plants is to be inspected and checked at
regular intervals. Defects such as loose connections or scorched cables must be
rectified immediately.
1.6.1.5
Necessary work on live parts and elements must be carried out only in the
presence of a second person who can cut off the power supply in case of danger
by actuating the emergency shut-off or main power switch. Secure the working
area with a red-and-white safety chain and a warning sign. Use insulated tools
only.
1.6.1.6
Before starting work on high-voltage assemblies and after cutting out the power
supply, the feeder cable must be grounded and components, such as capacitors,
short-circuited with a grounding rod.
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1.6.2
Gas, dust, steam and smoke
1.6.2.1
Carry out welding, flame-cutting and grinding work on the machine/plant only if
this has been expressly authorised, as there may be a risk of explosion and fire.
1.6.2.2
Before carrying out welding, flame-cutting and grinding operations, clean the
machine/plant and its surroundings from dust and other inflammable substances
and make sure that the premises are adequately ventilated (risk of explosion).
1.6.2.3
Observe any existing national regulations if work is to be carried out in narrow
rooms.
1.6.3
Hydraulic and pneumatic equipment
1.6.3.1
Work on hydraulic equipment may be carried out only by persons having special
knowledge and experience in hydraulic systems.
1.6.3.2
Check all lines, hoses and screwed connections regularly for leaks and obvious
damage. Repair damage immediately.
1.6.3.3
Depressurize all system sections and pressure pipes (hydraulic system,
compressed-air system) to be removed in accordance with the specific
instructions for the unit concerned before carrying out any repair work.
1.6.3.4
Hydraulic and compressed-air lines must be laid and fitted properly. Ensure that
no connections are interchanged. The fittings, lengths and quality of the hoses
must comply with the technical requirements.
1.6.4
Noise
1.6.4.1
During operation, all sound baffles must be closed.
1.6.4.2
Always wear the prescribed ear protectors.
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1.6.5
1.6.5.1
Oil, grease and other chemical substances
When handling oil, grease and other chemical substances, observe the productrelated safety regulations.
1.6.5.2
Be careful when handling hot consumables (risk of burning or scalding).
1.6.6
High temperature
It is emphasised the machine/plant in operation contains many very hot parts.
Care must be taken when approaching the machine to make replacements or
adjustments. It is necessary to provide fencing and guarding around the
restricted area and provide personnel with protective clothing, gloves, spectacles,
helmets, etc.
1.7 Mobile machinery and equipment

(Machinery and equipment used at frequently changing places of operation)
1.7.1
For loading only use lifting gear and tackle of sufficient capacity.
1.7.2
Appoint a competent marshaller to assist in the lifting operations.
1.7.3
Lift machinery and equipment properly with suitable lifting gear and only in
accordance with the operating instructions (fixing points for lifting tackle, etc. . . .).
1.7.4
Only use suitable means of transport of adequate carrying capacity.
1.7.5
Fasten the loads safely using the suitable fixing points.
1.7.6
Before or immediately after completion of the loading operations the
machine/plant must be secured by means of recommended/supplied devices
against unintentional changes of position and a corresponding warning sign
attached to the machine/plant.
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1.7.7
Before recommissioning the machine/plant these devices must be properly
removed.
1.7.8
Carefully refit and fasten all parts to be removed for transport purposes before
recommissioning the machine/plant.
1.7.9
Cut off the external power supply of the machine or plant even if only minor
changes of place are envisaged. Properly reconnect the machine to the supply
mains before recommissioning.
1.7.10
For recommissioning only proceed in accordance with the operating instructions.
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Control system
2
Electronic logic controller

The machine is controlled via programmable logic controller system Simatic S7300. The machine sequence program, the logic linkages, is stored in the program
memory, an EPROM. Connection to the machine is accomplished via the I/O
groups.
Within the control system, no wiring whatever is used to produce the logic
linkages. This means that, in this region, no faults due to loose wires, poor
soldering, or wire breakage can occur.
Further advantages are the control via keyboard and data display via a VDU
(Video display unit) or LCD (Liquid crystal display) and the storage of variable,
article dependent data on a data carrier, when this option has been chosen.
Further information on the structure of the control system and assemblies is
given in the Simatic S7 manual covering Logic Controller S7-300 Automation
Systems on the attached CD-ROM Technical Documentation.
Danger: For any maintenance switch off the controller and lock main
switch, to avoid hazards!
Do never pull plugs, when they are current-carrying!
Do not disconnect any current-carrying cable!
Structure of control cabinet

The control essentially comprises following parts:
Main switch on side or on front of cabinet.
Plugs and sockets on side of cabinet or inside cabinet coded and provided
with numbers to eliminate confusion.
Fan or cooling unit.
Attention: Change filter mats in regular intervals. Keep cabinet

doors closed because contamination of electronic parts will destroy
modules.
Over voltage protection: eliminates high voltage peeks and protects against
most lightning strikes (fuses in supply line fail), because of this electronic
modules could be destroyed. Isn't it possible to put the fuses in place
again or you can see any destruction at the unit (black burned
component inside) it must be changed! Does only occur at direct lightening
strikes to the supply line of cabinet.
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There are a lot of possibilities where lightning can strike, because of this a
perfect protection is not possible. But there are some more possibilities to
protect your line against lightning strikes, please contact WALTEC Company.
Fuses,
Switch contactors,
Relays for manual operation, because of safety in manual operation the
function may not be actuated through the electronic control.
Relays for release of automatic functions.
Programmable logic controller system with input, output modules and mains
unit.
Control panel for manual operation.
The control cabinet is to be installed so that it is protected from direct solar
radiation, direct radiation from the glass melting trough or other heat radiation.
Attention: Maximum temperature of environment for cabinet with

cooling unit is 40C, without cooling unit 20-25C!
Description of the Functions in the Control Cabinet

The following describes the general operating instructions for the controller via
the keyboard and screen and further operating elements (switches, pushbuttons
on the front panels).
Operating Elements
The labeling of the elements can be found in the circuit diagram located on the
backside of the front panel. The labeling contains the following information:
Example: 9S3 => Circuit Diagram Page 9 Switch Number 3
S
P
R
Switch or Pushbutton
Lamp or Indicator
Potentiometer
With this information, you can easily find the corresponding input in the controller.
It enables you to check the function of the element.
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4.1
Screen and keyboard
4.1.1 Description of the screen
Figure 1: SIMATIC IPC277
4.1.2 Function Description

The machine is controlled via touch screen as well as via the switches in the
control panel. Via switches 0-I the different machine functions can be switched
on and off.
The control system is structured as a follow-on control system. After switching on
the control, after some seconds the first screen appears. Going out from this
screen, with the touch screen you can request the other screens.
4.1.3
Screen Description
See device manual
Siemens_BA_Simatic_IPC277_en.pdf &
of CD-ROM on Documents for Electrical assemblies
In the following the most important screens of the machine control are
explained.
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4.1.3.1
Screen Description: BASIC MASK

Permanent
window
This mask starts automatically.
Message
line
Figure 2: Basic mask
With help of the screen masks the plant can be controlled and observed. With the
function keys (F01 to F12 & S01 to S18) you can choose all masks.
Key overlay of basic mask:
F01: Language select
F02: Master axis
F03: Curve management
F04: Plunger curves
F05: Manual operation mode
F06: Assembly area/temper
S02: Exit
S07: Message display
S08: Data record processing
S09: Program information
F07: Shears
F08: Gob chute
F09: Shears spraying
F11: Service
S16: Faults master drives MC
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Reference: This and the following screens can be used to check various states of
the plant and to set various parameters and options. How data are
entered in the fields is explained in Siemens, Simatic HMI, IPC277
Multi Panel on the attached CD-ROM Manuals for Electronic
Devices.
Data in permanent window:
Function
Meaning
Program:
Display of the currently processed program.
Cycles:
Display of the currently produced piece number per minute.
Operation mode
Display of the currently set operating mode of feeder, e.g.:

MANUAL. Further displays are: AUTOMATIC, REFERRING (only if
a positioning axis is available).
Counter:
Display of the piece number produced by this point in time. In

manual operating mode you can reset the piece count to zero.
Enter with the keyboard "0" and then confirm with ENTER .
Date and time:
The date and clock time are set in the Mask Setting date and time
(S12 of Service).
Oper. messages:
In the message line of the permanent window is displayed the

operating messages of the control system and the unit as a whole.
When reason of operating messages is cancelled, message
disappears by itself.
Fault messages:
Fault messages are also displayed in the message line of the

window immediately after occurring. They are marked by red back
colour. With the ACK key, you can quit the fault messages. If
more than one message is present, then further messages appears
after first one is quit. When messages are present the lamp inside
key F11 is flashing. By pressing this key you reach figure
"Messages" where you can branch to the operating messages or
the fault messages , they can be leafed through with the keys and
.
Actual temper.
Actual temperatures of both linear motors for plunger mechanism

and shear drive are displayed.
If an error occurs, the screen shows an icon at S10 in each mask, when
pressed you will be forwarded to the mask Faults SINAMICS.
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4.1.3.2
Screen Description: MASTER AXIS
F02 from Basic Mask
Figure 3: Master Axis
Function
Master axis
Meaning
Virtual master axis which can be synchronized by external start
pulses.
There are two operating modes:
1) internal: virtual axis is freely running with speed set by
parameter int. setpoint value. This is the usual setting.
2) external pulse: virtual master axis gets synchronized by external
impulse.
Position the cursor into the field and press ENTER, select the
Int. setpoint value
source
and acknowledge with ENTER.
Enter here the amount of cuts that the machine should perform if
Differential
the source is set to internal, e.g. 20,0 /min

Phase shift for start of shear.
23
WALTEC
Function (cont.)
Actual speed
Actual position
Interface
Feeding active
Press in feeding
Press in STOP
Glass level plus
Glass level minus
Meaning
Displays the speed of the machine in cycles/min.
Displays the actual position of the virtual master axis in
(synchronized with the external impulse or free-running).
Display of signals which are exchanged between feeder and press
machine. Signals can be transferred by wire or by bus.
When feeder is actually feeding signals will be send to press.
Signal from press machine to feeder that press can be fed with
glass.
Signal from press that machine is in STOP condition and can not be
fed with glass.
Signal from press to increase gob weight.
Signal from press to decrease gob weight.
24
WALTEC
4.1.3.3
Screen Description: CURVE MANAGEMENT
F03 of Basic Mask
Figure 4: Curve Management
Key overlay of this mask:

F01: Basic Mask
F02: Master axis
F03: Plunger trace function
F04: Plunger curves
F05: Manual settings
F06: Manual settings

F07: Shears
F08: Gob chute
F09: Gob Gute
F11: Interpolation reset
Function
Coupling A->B/C
Meaning
The modification of curve A is coupled directly to curve B and C.
Every change that is operated on the curve A is transferred to curve
B and C. If you switch coupling off, it is possible to modify each
curve separately.
Copy curve
At this point select which curve you want to copy, e.g. A to S,

or B to S and quit with ENTER. After this you can copy e.g. curve S
to B, or S to C.
Memory
Graphical display of the curve, which is currently in the memory (S).

This is an intermediate memory to copy curves. The memory
content is not processed.
25
WALTEC
F03 of Mask Curve Management
Figure 5: Plunger trace
26
WALTEC
4.1.3.4
Screen Description: PLUNGER CURVE
F04 of Basic Mask
Straight line
interpolation
Plunger stroke
Spline Interpol.
Figure 6: PLUNGER CURVE

F01: Basic mask
F02: Plunger curves
F04: Redraw plunder curve
Function
Plunger curve
F06: Add intermediate point

F08: Delete point
F10: Shears
F11: Spraying
Meaning
Plunger curves A to C can be programmed on this page, just by
defining point-data. Minimum two points are required for definition
of curve. Point-data consists of three values (angle, position and
acceleration).
Actual value
Points
Lowest position
Stroke
vmax
Actual position of the plunger in mm. If an electrical axis is still not

referenced, then actual position value will blink yellow / blue.
Number of active points.
Lowest position of the plunger curve, e.g. 10.000mm.
Total stroke of the plunger curve during one cycle, e.g. 26.800mm.
Maximum speed of the plunger during the cycle, e.g 35 mm/s. This
value relates to one degree of the timer.
27
WALTEC
Function (cont.)
amax
Meaning
Maximum acceleration of the plunger during the cycle, e.g. 288
mm/s. This value relates to one degree of the timer.
Curve shift
This input value will shift entire curve. Positive values shift the curve
upwards and negative values shift the curve downwards. After
shifting curve value will be set automatically to 0mm.
Stroke
Shear start
Table
Angle
Parameter is used to increase / decrease the gob weight manually.

Input value for adjusting the total stroke of the plunger.
Enter here the desired cutting point of the shear cut in . Cutting
angle will be displayed also in curve.
Contains all point-data which defines the curve. Maximum 16 points
can be defined. Active point is highlighted and surrounded by green
frame. Each point-data consists of three values (angle, position and
acceleration).
This defines the position of the point on the horizontal axis. The
angle refers to the timer.
Position
This defines the vertical position of the point (stroke).
Acceleration
The drive accelerates to change the trajectory. If the acceleration to

the next point is too small, the interpolator increases the value as
long as the next given point will be achieved. The lower the
acceleration, the softer is the plunger movement which will also
reduce the mechanical load and stress.
Note: If the feeder is stopped with Feeder Stop or with Plunger 0-I, it
first stops at the bottom position and then moves to the Auto-Stop position
which is defined in service area / machine parameter. The plunger stops
immediately if you press Emergency Off or if you switch to MAN.
28
WALTEC
How to manage number of points in plunger curve:

1. Insert new points
Set the cursor to a field, after that a new point shall be inserted (e.g. point 4).
Push the key F06

for insert a new point.
When the cursor was at an active point, there will appear two new keys
for accept or
for cancelling this action.
to execute this function.

If you are sure, push key
A new point will be generated between the actual point and the following (e.g.
point 4 and 5). It is placed exact between the old points, but in linear
interpolation. So the shape of the curve is nearly the same as before, but there is
a new point in the middle of the old ones.
Now place the cursor to the new point and change the values as you need.
2. Delete points
Set the cursor to a field, which shall be deleted.
Push the key F08

for deleting an existing point.
When the cursor was at an active point, there will appear two new keys
for accept or
for cancelling this action.
If you are sure, push key

to execute this function.
The actual point will be deleted.
The system will not allow deleting point 1, or generating a curve with less than
two points!
29
WALTEC
4.1.3.5
Screen Description: PLUNGER CURVE POSITION + SPEED
F05 of Plunger curve
Figure 7: PLUNGER CURVE POSITION + SPEED
30
WALTEC
4.1.3.6
Screen Description: PLUNGER MANUAL
F05 of Basic Mask
Figure 8: Plunger - Manual

F01: Basic mask
F02: Master axis
F04: Plunger curves
Function
Step
Actual values
Plunger
(linear motor)

F07: Shears
F08: Gob chute
Meaning
Displays the step of the program process. It is used to locate
program errors. In case of program failures please forward the
pertaining number to the WALTEC Company.
Actual values for plunger and shear position, revolving tube speed
and motor temperatures are displayed. If an electrical axis is still
not referenced, then actual position value will blink yellow / blue.
Three different speed ranges can be fixed that define for the
manual-operating mode the maximum speed of the plunger stroke
With this function you can determine e.g. to travel slowly in the
31
WALTEC
Function (cont.)
Plunger (cont.)
Position
Meaning
glass and to travel fast in the upper area towards the assembly
position.
Upper software position limit of plunger, e.g. 174mm.
Position
(high Override)
Position
(low Override)
From this position upwards plunger will move with setpoint-speed

multiplied by high override, e.g. 55mm/s*100%=55mm/s.
From this position downwards plunger will move with setpointspeed multiplied by low override, e.g. 55mm/s*10%=5.5mm/s.
In between these two positions override will be gradually changed.
Lower software position limit of plunger, e.g. 0.000mm.
To prevent collision of plunger tip with orifice in manual mode this
value must be checked carefully. If you are not sure increase this
Position
Shear
(servo motor)
value.
If keep on jogging forward / backward shear will always make a
180 turn. In other words shear will be fully open of fully closed. In
Speed
Revolving tube
(async. motor)
automatic mode of course shear will move a full cycle of 360.

Maximum travel speed of the shears in manual-operating mode.
Revolving tube height can only be adjusted manually by crank
mechanism. Actual height above feeder channel bottom is
displayed on scale.
Setpoint value
Direction of
rotation
Enter here number of rotations per minute.

Can be set clockwise or counter-clockwise.
Motor
Actual speed and torque of asynchrone motor revolving tube are

displayed. If tube is set too low torque will increase because of
friction and rotation will be automatically stopped to prevent
damage of tube and channel. Maximum allowed torque can be set
in service / limitations.
Motor fault
If there is an active motor fault an exclamation mark will be

displayed. Just tap on this mark to go automatically to related fault
page for Sinamics drives. There you can access also pdfdocumentation about Sinamics drives and Technology PLCs.
Actual values or output fields are mostly displayed in blue colour. Some
actual timing or position values are displayed in red colour. Setpoint values or
input fields are always in yellow colour with red background colour!
32
WALTEC
Position and speed settings made on the manual pages are only valid in
manual mode of the feeder! Exception: Speed-setting of revolving tube can
be set only here and is valid always.
33
WALTEC
4.1.3.7
Screen Description: PLUNGER (Assembling / Tempering)
F06 of Basic Mask
Figure 9: Plunger (Assembling / Tempering)

F01: Basic Mask
F02: Master axis
F04: Plunger curve
Assembling:
Press jog up
F05: Operation mode manual

F07: Shears
F08: Gob chute
Tempering:
Press jog down
34
WALTEC
Function
Plunger
Meaning
In automatic mode of plunger jog up and down button (see picture
above) can be used for assembling and tempering of plungers.
Assembling
When feeder is stopped in automatic mode (red stop button has

been pressed) and jog up button has been pressed then plunger
will move up automatically to assembly position. When being in top
position old damaged or worn plunger can be removed and new
Position
Position
(high Override)
Position
(low Override)
Tempering
plunger assembled.
Upper assembling position of plunger, e.g. 174mm.
From this position upwards plunger will move with setpoint-speed
multiplied by high override, e.g. 50mm/s*80%=40mm/s.
From this position downwards plunger will move with setpointspeed multiplied by low override, e.g. 50mm/s*20%=10mm/s.
In between these two positions override will be gradually changed,
e.g. from 20% to 80.
When feeder is stopped in automatic mode (red stop button has
been pressed) and jog down button has been pressed then plunger
will start automatically to temper plunger. Tempering will prevent
Start
Steps
too fast heating and possible cracking of new plunger.

Tempering will be started from this position with speed set.
Tempering process will make totally 15 position steps lasting totally
5minutes to reach end position.
End
Tempering will end when this position is reached with speed set.
Actual values or output fields are mostly displayed in blue colour. Some
actual timing or position values are displayed in red colour. Setpoint values or
input fields are always in yellow colour with red background colour!
35
WALTEC
4.1.3.8
Screen Description: SHEARS
F07 of Basic Mask
Figure 10: Shears

F01: Basic Mask
F02: Master axis
F04: Plunger curves

F08: Gob chute
Function
Step
Meaning
Displays the step of the program process. It is used to locate
Actual values
program errors. In case of program failures please forward the

pertaining number to the WALTEC Company.
Actual values like shear position in [], speed in [%] and so on are
Override
displayed. If an electrical axis is still not referenced, then actual

position value will blink yellow / blue.
The shear drive travels with this override. This means e.g. 50% of
the maximum velocity of the drive. Press calc!-button to
36
WALTEC
Function (cont.)
Override (cont.)
Meaning
recalculate shear movement. In case calculation time is too long,
press reset!-button.
Shear closed /
Angle shift
v_max, a_max
Actual angle in [] when shear blades are closed (when glass is

cut).
actual speed and acceleration is displayed. If these values gets to
the limits an error message is displayed. Then reduce acceleration
Curve points
and speed if possibly.

Point-data consists of three values: angle, position and
acceleration. Two points are needed to define shear movement.
Changing of shear blades:

Shear got its own safety circuit which should be used when changing shear blades.Just
switch off the electrical power with key switch. Plug out key for preventing that while in
danger zone somebody else will switch back on. Take key and change shear blades.
Plug in key and switch on and press green button to activate power for shear drive.
( noch Bilder einfgen)
Danger: When changing shear blades or working in danger area close to

shear mechanism, please always switch shear to sate off by using key
switch on operator panel. Operator in charge has to store key in secure
place. Only operator in charge should repower shear.
37
WALTEC
4.1.3.9
Screen Description: SHEARS SPRAYING
F09 of Basic Mask
Spraying
Function
Piece
Delay time
Meaning
Defining after how many cuts spraying is activated, e.g. with setting
above each second time shear blades will be sprayed.
The delay time after which the spraying is started, upon the
Time
initiation of the spraying cycle, e.g. 0.1s. The spraying cycle is

started after the shear cut when shear is fully open.
Spraying time in seconds, e.g. 0.30s. For example to remove
Active
Chute spraying
excess water after spraying the on timer for air should stay on
longer.
Display when valves are actuated.
On timer for chute spraying.
38
WALTEC
4.1.3.10 Screen Description: GOB CHUTE / ADDITIONAL FUNCTIONS

F08 of Basic Mask
Figure 11: Gob chute

F01: Basic Mask
F02: Master axis
F04: Plunger curves

F07: Shears
Function
Shear cut
Meaning
Setting when shear blades are closed.
Chute forward/
Backward
Setting of cam position when chute shall travel forward or

backward. The cam must be adjusted so, that the chute travels
exactly between two successive gobs.
Flipper
Release from
Press
Option, ZF1..4
Setting of cam position when flipper will be actuated (option).

Display of enabling signal from press.
Five digital outputs can be adjusted by cam on off settings. Cam
can be switched ON and OFF by touch-button. For example: Option
cam digital output is switched ON and will be set to High-Level
when virtual master axis reaches 58.7, and will be set to LowLevel when virtual axis reaches 148.5.
39
WALTEC
4.1.3.11 Screen Description: SERVICE MASK

F12 of basic mask
Figure 12: Service
After pushing F8 and entering the password 100 confirming it with ENTER , you can
select various masks with the aid of the screen via the function keys.
Important Note: During set-up of the machine/device all machine data are set
by the service engineers of the WALTEC Company. Even after the
machine/device has been handed-over to the user, the machine data may be
changed only by personal, trained by service engineers of the WALTEC
Company!
Key overlay of service mask:
F01: Return to basic mask
F02: Status-Profibus
F03: Machine data Sinamics
F04: Limitations
F05: Lubrication
F06: Diagnosis Micromaster

F07: Status Sinamics
F08: Status CU320
F09: Status Infeed
40
WALTEC
S05: Logout
S06: Login
S07: Message display
S08: Status of digital inputs/outputs
S09: UPS Status
S14: Language select

S15: Status / control
S16: Faults Sinamics
S17: Password list
S18: Management date and time
41
WALTEC
4.1.3.12 Screen Description: STATUS PROFIBUS

F02 of Service Mask
Figure 13: Status Profibus
Indication:
In the left column the current status will be shown. In the second column a
short breakdown of the connection will be indicated. The time of
breakdown will be stored.
Green hook stands for Profibus o. k.
Red exclamation-mark stands for fault Profibus.

Time of breakdown will be recorded.
42
WALTEC
4.1.3.13 Screen Description: MACHINE DATA MC

F03 of service mask
Figure 14: Machine Data MC
Danger: All data should only ever be changed by personal, trained by

service engineers of the WALTEC company! Improper changes may lead
to personal injury and serious machine damage!
Function
Machine data
Meaning
Parameters for incremental (relative) encoders and servo axis.
After power off all servo motors containing relative encoders will
loose its actual position and needs to find (home) reference point
again! If an electrical axis is still not referenced (homed), then
Reference point
coordinate
Reference point
Shift
Jog velocity
New ref. point
actual position value will blink yellow / blue.

In ref.-mode axis is looking for ref.signal then stop and set current
position to this parameter.
In ref.-mode axis is looking for ref.signal then stop moves this distance and then sets actual position value to zero.
When axis is not referenced this parameter defines how fast axis
will move.
If touch-button is tapped axis can be referenced again.
43
WALTEC
4.1.3.14 Screen Description: LIMITATIONS

F04 of Service Mask
Figure 15: Limitations
Function
Limitations
Acceleration
Meaning
The maximum speed and the maximum acceleration can be
entered on this mask, which dependents on the physical condition
of the drive. This is performed by the WALTEC company at startup. These values refer to the actual resulting speed and
acceleration of the axis depending on the current cycles. This
means that the current cycles are included into the calculation and
is compared with the limits when the plunger curve is changed. An
error message appears on the mask and the last loaded curve is
activated should the set limits be exceeded.
Definition of the maximum allowed traveling speed of the plunger
stroke to the synchronous point.
Definition of the maximum allowed acceleration of the plunger
Calculated speed
Calc. accelerat.
stroke. Also shear acceleration can be limited [0..100%].

Actual speed set according to cam definition for plunger.
Actual acceleration set according to cam definition for plunger.
Maximum speed
Max. upper dead

point
Software limit of topmost position of plunger stroke, e.g.170mm.
44
WALTEC
Function (cont.)
Position AutoStop
Meaning
When plunger is stopped in Automatic-mode it will move to this position and then stop. Can be used to adjust glass flow when feeder
Min. lower dead

point
is not running.
Software limit of lowest position of plunger stroke, e.g. 10mm. To
prevent collision of plunger tip with orifice in this value must be
checked carefully. In automatic plunger tip can not move below this
Speed start
position
Revolving tube
limiting value.
When plunger is started it will move to start position with this
speed.
Actual torque of asynchrone motor revolving tube is displayed. If
tube is set too low torque will increase because of friction and
rotation will be automatically stopped to prevent damage of tube
and channel. Maximum allowed torque can be set in service /
Maximum torque
Gob weight
control
limitations.
Setpoint value for maximum torque of motor, e.g. 0.99 Nm.
When feeder gets signal from press to increase or decrease gob
weight, plunger cam will be lifted up or down according to
Absolute
parameters listed below.

When feeder gets signal to change gob weight it will lift up or down
plunger cam according to this value, e.g. 0.1mm.
Actual value of total shift of plunger since feeder started.
First and last

point
Defines on which points this incremental shift will act, e.g. with setting above all point 1 to 8 will be shifted up or down 0.1mm if gob
Incremental shift
weight needs to be controlled.
45
WALTEC
4.1.3.15 Screen Description: LUBRICATION

F09 of Service Mask
Figure 16: Lubrication
Function
Meaning
Lubrication
Amount of oil being used can be adjusted. Too less oil will damage
linear guides or linear motor plunger mechanism.
Counter
Amount of cuts after lubrication has been started, e.g. 300 pieces.
The amount of the already processed cuts can be read in the front
of the field, e.g. 178.
Lubrication interval time is calculated automatically and displayed.
Impulse:
Lubrication duration in seconds, e.g. 3.00s.

Status of valve and pressure switch are displayed. Lubrication
valves can be actuated manually by pressing softkey valve on.
Note: Set the impulse duration at least so long that the lubrication pump can
totally complete its cycle, otherwise a sufficient lubrication cannot be guaranteed!
On manometer oil pressure must be higher than approximately 60 bar.
46
WALTEC
4.1.3.16 Screen Description: DIAGNOSIS MICROMASTER

F06 of service mask
Figure 17: Diagnosis Micromaster
Function
Meaning
Diagnosis
On this page actual values, control and status words of all

Micromaster inverter can be monitored.
Axis
Status
Tap on selection box to select Micromaster inverter.

Actual values for frequency, motor current, motor torque, DC link
voltage, motor speed, output voltage and converter temperature are
displayed.
Control and
Status word
RFG
Displays active status and control word of inverter (in binary form)
and can be used to diagnose which commands are active.
Ramp function generator: Ramp timings control the time that is
taken to either start the motor and ramp it up to the required speed
(ramp-up) or the time it takes to slow the motor down, normally to a
standstill (ramp-down). The default ramp timings for both ramp-up
and ramp-down is typically 3 seconds for our application.
If the ramp timings are set too short, the inverter will protect the
system by tripping with an overcurrent or overvoltage fault.
See circuit diagram page 20 how to set parameters for new
Micromaster inverter. Profibus address is set by dip-switches.
47
WALTEC
48
WALTEC
4.1.3.17 Screen Description: STATUS SINAMICS

F07 of service mask
Figure 18: Status Sinamics
Function
Meaning
Diagnosis
On this page actual values, control and status words of all Sinamics
servo amplifier can be monitored.
Axis
Drive actual
Tap on selection box to select sinamics drive.

Actual values for speed, output current, DC link voltage, motor
values
Technology
speed, converter workload are displayed.

Displays active status of Sinamics drive (in binary form).
Drive enabled
Done
The axis is enabled and ready to be controlled via motion control

tasks.
The axis is homed and is capable of executing absolute positioning
tasks. If an electrical axis is still not homed (referenced), then
actual position value will blink yellow / blue.
The axis finished executing task.
Error
Standstill
Positioning Com.
An error has occurred in the "Axis" technology object.

The axis is at a standstill.
The axis executes a positioning task.
Speed Command
Synchronized C.
The axis executes a speed control task.

The axis executes a synchronous task.
Homing done
49
WALTEC
Function (cont.)
Homing
Follow up control
Meaning
The axis executes a homing (referencing) task.
The axis is in follow up mode.
HW Limit SwitchHW Limit Switch+
The lower (negative) hardware limit switch has been approached.

The upper (positive) hardware limit switch has been approached.
50
WALTEC
4.1.3.18 Screen Description: STATUS CU320

F08 of service mask
Figure 19: Status CU320
Function
Meaning
Status CU320
Status of digital input signals is displayed. Because of security

reasons and to be able to detect cable breaks some signals may be
Emergency-Stop
inversed.
Feeder is in emergency stop state.
Shear safe off

Infeed in operat.
Shear drive is in safe stop state.

Infeed module is in operation.
Plunger lower
hardware limit
Plunger upper
hardware limit
Plunger A (B) lower hardware limit switch is actuated.

Plunger zero position is near orifice.
Plunger A(B) upper hardware limit switch is actuated.
51
WALTEC
4.1.3.19 Screen Description: STATUS INFEED

F09 of service mask
Figure 20: Status Infeed
Function
Meaning
Sinamics supply
Control word
Status and control word of infeed module is displayed.

Control bits send from PLC to infeed module.
Status word
Status bits send from infeed module to PLC.
52
WALTEC
4.1.3.20 Screen Description: STATUS CPU

F10 of service mask
Figure 21: Status I/O T-CPU
Function
Meaning
Status I/O T-CPU
Status of digital input and output signals of technology PLC are

displayed. Also the maximum and actual time of program loop can
Input
be monitored.
Status of all reference point (homing) proxies is displayed. Can be
used to test if electrical connection or proximity switch is still
working correctly.
Output
Max Loop
Duration
Cmd Loop
Duration
Status of shear starting impulse and additional functions Cam1 to

Cam4 is displayed.
Command execution is not tied to a fixed cycle and depends on the
number of busy commands and on CPU load. The maximum (Max
Loop) and average task (CmdLoop) execution time can be read.
53
WALTEC
4.1.3.21 Screen Description: STATUS DIGITAL OUTPUTS / INPUTS

S08 of service mask
Figure 22: Status digital outputs
F03 of digital outputs
Figure 23: Status digital inputs
54
WALTEC
4.1.3.22 Screen Description: UPS STATUS

S09 of service mask
Figure 24: UPS Status
UPS is used in case of external main voltage fault to allow plunger

and shear drive to move to secure positions. Shear will open totally.
Plunger will move to Auto-Stop position.
Function
UPS Status
Meaning
Actual state of UPS (uninterruptable power supply) can me
Setup operation
monitored. Page it is also used for adjustment of scaling.

1) To be able to charge battery pack (2*12V) 24V power supply
needs to be adjusted by potentiometer to 27 Volt.
Actual values
2) Open the bridge between the two batteries.

3) Adjust gain parameter for power supply and battery as long as
you get 27 Volt for power supply and battery.
4) Close the bridge between the two batteries.
Actual charging voltage and current are displayed. Also DC power
of 24V power supply.
55
WALTEC
4.1.3.23 Screen Description: STATUS/CONTROL

S15 of service mask
Figure 25: Status/Control
Danger: Changes to the PLC internal data should only ever be made by
service engineers of the WALTEC Company! Improper
changes may lead to personal injury and serious machine
damage!
Function
Meaning
Connection
Type
DB-Nr.
Submenu with the selection of the PLC

Submenu with the selection of DB, I, O, F, T, C
Input of the desired data block
Offset
Bit
Data type
Format
Start address of I, O, F and data DBW, DBD, DBB

Bit of start address I, O, F and data DBW, DBD, DBB
Selection of the desired types of the dates: BIN, HEX, DEC
Selection of the: CHAR; WORD; INT; DWORD; DINT; REAL
Status Value
Actual value
56
WALTEC
There is the possibility of the observation of the status values up to the

individual bits. Even control of each individual bit would be possible.
4.1.3.24 Screen Description: PASSWORD LIST
S17 of service mask
Figure 26: Password list
Function
Password list
Logoff time
Group
Password
User
Meaning
Contains all password and user names. Administrator can assign
new user with new password and access level.
Time after which account is automatically locked.
Different groups got different access levels. Only account with
highest level can change every parameter and access all pages.
Each operator can be assigned an own password
Each operator can be assigned an own username.
57
WALTEC
4.1.3.25 Screen Description: DATE / TIME

S18 of service mask
Figure 27: Date / time
Function
Date and time
S7 CPU time
Windows time
Meaning
Used for synchronizing of PLC time with panel time.
Internal date and time of programmable logic controller (PLC).
Internal date and time of operator panel.
Set time
S18
Input fields for entering actual date and time

Touch-button for synchronizing PLC and panel time.
58
WALTEC
4.1.3.26 Screen Description: Message display

S04 from Basic mask
Figure 28: Message display
At the message display are defined specific views of messages, which are arrived or
acknowledged. For that exists several filter possibilities.
Status of massages:
Back color:
K = message is arrived
Yellow: Operating message
KQ = message is arrived and

acknowledged
Red, blinking: Fault message is arrived
G = message is gone
Red, continuous: Fault message is

arrived and gone
White: after acknowledging with ACK
59
WALTEC
4.1.3.27 Screen Description: Message archive

F03 from Message display
Figure 29: Message archive with printer function.
60
WALTEC
4.1.3.28 Screen Description: CPU diagnosis cache

Figure 30: CPU diagnosis cache
In this screen the system messages of the CPU can be monitored.
61
WALTEC
4.1.3.29 Screen Description: Change log

Figure 31: Change log
62
WALTEC
4.1.3.30
Screen Description: Data Record Processing
S05 from Basic mask
Figure 32: Data record processing

F01: Back to basic mask
F02: Store
F03: Input in controller
F10: Data delete
In recipe field select with
F06: Import Excel table

F07: Actual data export
F08: Export of all stored data
and confirming it with ENTER.
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Data record name: Enter here the name of the data, which you wish to transfer, e.g.:
Feeder. You can also select a name from the contents.
F01: Back to the preceding mask.
F02: Secures the actual data on the selected medium
F03: Data input from a medium into the memory of the machine controller
F10: Deletes selected data from the medium.
F06: Imports Excel table into data set.
F07: Exports the finally stored data as an Excel table in format CSV in a determined
destination directory of the optional server.
F08: Exports all stored data sets as an Excel table.
Attention: It is only allowed to put in data when the machine is running in manual
operation mode.
How to manage data sets on CF-card:
1. Storing a program
If you want to store data on the medium, enter a new name in the first line of the
screen (new data record).
You can enter letters and numbers for the program name.
There is a multiple mating at each key on the MP370 keyboard. You can switch
over that by using the special A-Z key. If the key LEDs are off, you will get the
numbers. When you push the A-Z key one time, the left LED will be on and the
left side letters on the keyboard are activated. Pushing the A-Z key a second
time, the right LED will be on and the letters on the right side of the keyboard are
activated. Push the A-Z key a third time and the LED goes off. Now the
numbers are active again.
After entering your desired name for the actual program data, push the green
ENTER key to accept the name.
Now start transfer of data to Flash by pushing softkey F02

.
There will be a short message on the screen that confirms the action (success).
2. Loading a program
First you have to switch the machine to manual mode. It is not possible to load
another program during operation!
Move the cursor to the field data record name and push the green ENTER key
to get a short list of all your programs.
Select the desired program by moving the cursor through the list.
To choose the highlighted program push the green ENTER key, the list will close
and the chosen program name keeps in the field.
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Now push softkey F03

.
The program transfer to the PLC will start and a short message appears on the
screen.
Watch the message. If the transfer was successful, the actual program name will
be displayed in the first line of the permanent window of the screen. Go back to
the data screens (e.g. plunger curve) and look over the loaded data.
Now you can start production with the new loaded program!
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4.1.3.31 Screen Description: Program information

S06 from Basic mask
Figure 33: Program information
For all programs you can write, store and retrieve important notes (for example article
data etc.) with the help of this mask.
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4.1.3.32 Screen Description: Faults of electrical axis

S11 from Basic mask
Figure 34: Faults of electrical axis

This page displays actual faults of electrical axis. Check fault number and text and try to
solve problem. After repairing the malfunction(s) acknowledge fault by pressing ACKkey. Acknowledging is only possible in manual operating mode.
F07: Calling T-CPU documentation (Technology).
F08: Calling Sinamics servo amplifier documentation.
F09: Calling Micromaster frequency converter documentation.
There will be displayed three types of fault numbers labeled with:
T
Technology related faults
F
Servo amplifier related faults
W
Servo amplifier related warnings
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Switching machine on and manual operation

Set switch "MAN-AUTO-REF" to manual.
Set main switch(es) on side or in front of control cabinet to "I".
Push "Emergency off Reset" key. All Emergency off keys have to be
unlocked!
Approaching of reference points
For axes with limited stroke or rotation such as take-out or turning
device: Move the axes with the manual push-buttons to the coloured
markings or markers for basic setting (not necessary for endless axes).
Attention: The axes must be moved one after another to the markers so, that
no collision with any machine parts can occur. No safety locks are provided!
Turn switch MAN-AUTO-REF to REF =reference point.
Press reference point pushbutton.
When the reference point is reached the lamp in the reference point
pushbutton does not longer flash and the corresponding message
disappears from the screen.
Turn switch MAN-AUTO-REF back to MAN =manual operation.
Reference: If the machine is operated in manual operation, before approaching
the reference points a limit switch, limiting the movements of an axis, can be
approached. To travel away from the limit switch the reset button of this axis
inside the control box or at the operator panel must be pushed and at the
same time the corresponding directional pushbutton.
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6 Initial position of the machine and automatic operation

6.1 Initial position
Shears completely open
Plunger is in synchronisation position (at 0)
Reference: If plunger mechanism starts, first the plunger drives below and
synchronizes with master axis.
6.2 Engagement of automatic mode

The machine initiates automatic mode after switching over to AUTO and pressing
key Cycle Start.
The control calculates with aid of curve at the VDU and the desired cuts per
minute the speed of servo axis and travels the concerning strokes.
Not all assemblies must be switched in at engagement of automatic mode. For
instance plunger stroke, shears and so on can be switched in only as required by
manufacturing sequence.
6.3 Settings in automatic mode

In automatic mode, all values available for alteration can be altered on the
operator panel Choose the needed field in a screen and alter the value with the
keyboard.
6.4 Shutting off the machine

When you want to switch off plunger mechanism, stop the glass flow in the well
know way or limit it and drain it. Look absolutely at sufficient cooling.
You can switch off all modules with the switches (0-I to 0) at the control panel.
Change over from automatic to manual mode. Switch off all motors and at last
main switches.
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Malfunction in Automatic Mode and EMERGENCY-OFF

If a production malfunction occurs for example you can switch off the shears or
other particular units via mushroom buttons on the machine. All other machine
functions continue to run. Through actuation of the small button located to the
mushroom button you can release the blocked function. The unit reruns in the
next machine cycle.
Danger: If you want to work on the facility you switched off with "STOP" or you
work in the danger area of the facility you must shut off the facility also with preselection switch "0-I".
You have to delete the indicated error messages with the button F15 in manual mode.
Reference: You have to delete the error message of an electric axis, before you
can move it
Emergency-off
The machine stops immediately through actuation of the red emergency-off
button, all motors are switched off and the control system is isolated from the
machine. The cullet chute travels into the glass flow. You have to restart the
machine to automatic mode, as described under preceding chapters.
Power failure
For power failure proceed like Emergency-off procedure. With aid of battery at
power failure, open the shears and travel the plunger upward.
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Malfunctions and their Rectification S7-300

Most machine malfunctions are indicated via display.
Other malfunctions should be localized as follows:
Open control cabinet
Check whether the green Run LED shows clearly. Switch on CPU
module must stand on position RUN. If the lamp does not show, check on
the terminal strip whether the 24 V supply voltage is available. If available
check if the LED DC 5V shows. If not exchange power supply module.
Check whether the red SF LED shows. If yes, see Operating manual of
Control S7-300 on CD-ROM Manuals for Electric Devices
If individual functions are not controlled in automatic mode, the machine remains
in automatic mode, and the control cabinet is opened. On the basis of the circuit
diagram, the number or the relevant output is sought and the output modules
checked as to whether the green LED indicates that the output is controlled.
If automatic operation is not possible, it can be checked via manual operation
whether the function is executed or whether the output is controlled. If the output
is controlled, the cable to the assembly and the appropriate part are to be
functionally checked.
Danger: During all operations in the control cabinet, on the terminal boxes,
and on the external electrical parts, other than test operations with test
appliances by an expert the main switch is to be switched off.
8.1 Overall Reset of the control S7-300

If the yellow "STOP" LED on the central processing unit (CPU) shows although
the CPU mode selector is set to "RN" (run) position, you must overall reset the
internal memory.
Proceed as described in Operating manual of Control S7-300.
The Step7 program is loaded automatically after successful "Overall Reset" from
the plugged EPROM module.
After Overall Reset you must load the program data from the disk into the internal
memory.
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9 Adjustments when Changing an Axes Drive

9.1 Necessity for Locating the Reference Point
Because of the use of resolvers in the positioning component group, once the
power supply is switched off the computer loses its current position. When the
power supply is turned on again the reference point must be located in order to
permit a later absolute positioning in automatic operation. It is only after the
locating of the reference point that the indicated required position value tallies
with the absolute required position of the axle in question with reference to its
zero-point.
9.2 Locating the Machine Reference Point

Within the possible process range, one machine reference point is defined and
retained permanently per axle in order to synchronise the computer with the
mechanics. For the rotary distance measuring resolver one cam is evaluated
(roughly) and one "zero point" (finely) for the resolver.
The reference point is selected in such a way that it can be found quickly and
easily after switching on. After starting the procedure for finding the reference
point, the cam is started with a contact-free limit switch at a fixed, preprogrammed speed. The "zero-mark" is approached, and if necessary displaced,
at a second speed. The reduction cam is connected via a rapid input on the front
side of the positioning component group.
The relocation of the reference point can be defined with machine date (MD)
Reference point
Zero mark of
resolver
1 revolution of
resolver
Cam
Signal of limit
switch
Travelling
speed of axis
Machine
zero point
Ref. point
shift
Figure 35: Reference point location
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9.3 Calculating the Reference Point Displacement

The unit of displacement is to be entered in millimetres for linear axes and for
round axes in degree. The plus or minus sign shows the direction of the
displacement of the reference point.
If a motor is replaced or the axis taken to pieces mechanically, the reference
point must be calculated again:
a) If it is still possible, the machine zero point must be measured and noted
before the motor is replaced. All positioning values relate to this machine zero
point. If this is no longer possible the old machine zero point must be found
with the aid of a clearly marked point with known coordinates (e.g. a marking
on the mechanics).
b) Replacement of the drive element if necessary.
c) Switch on the computer and select operating mode MAN. In the machine
data picture at the service level the machine data reference point must be set
to zero (=> machine zero point the same as the zero mark) on the axis in
question.
d) Select operating mode REF., so the machine data are transferred again.
Approach the reference point by pressing the key for the concerning axis. The
axis will now stop shortly after leaving the cam on the zero mark of the
resolver.
e) Select manual operation (MAN). Measure the distance from the axis to the
old machine zero point, or approach the machine zero point with the function
keys and read the value off from the mask. Enter this value in the machine
data reference point, using the plus or minus sign to show the direction of the
displacement of the zero point. If the machine zero point is unknown and some
other clearly marked point is being used, the difference must be calculated
{known coordinate value minus value actually existing} and entered into MD.
f) Switch the whole installation off and on again. Approach the reference point
and check, adjust again if necessary. The installation is now ready for
operation again.
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Index
control cabinet
control cabinet
cooling unit
Data record processing
Master axis
over voltage protection
18
19
18
63
24
18
positioning component group

reference point
Reference point
reference point displacement
resolver
zero point
72
72
72
73
72
72
Figures
Figure 1: SIMATIC IPC277 ............................................................................................ 20
Figure 2: Basic mask ..................................................................................................... 21
Figure 3: Master Axis ..................................................................................................... 23
Figure 4: Curve Management ........................................................................................ 25
Figure 5: Plunger trace .................................................................................................. 26
Figure 6: PLUNGER CURVE......................................................................................... 27
Figure 7: PLUNGER CURVE POSITION + SPEED ...................................................... 30
Figure 8: Plunger - Manual ............................................................................................ 31
Figure 9: Plunger (Assembling / Tempering) ................................................................. 34
Figure 10: Shears .......................................................................................................... 36
Figure 11: Gob chute ..................................................................................................... 39
Figure 12: Service ......................................................................................................... 40
Figure 13: Status Profibus ............................................................................................. 42
Figure 14: Machine Data MC ......................................................................................... 43
Figure 15: Limitations .................................................................................................... 44
Figure 16: Lubrication .................................................................................................... 46
Figure 17: Diagnosis Micromaster ................................................................................. 47
Figure 18: Status Sinamics ............................................................................................ 49
Figure 19: Status CU320 ............................................................................................... 51
Figure 20: Status Infeed ................................................................................................ 52
Figure 21: Status I/O T-CPU.......................................................................................... 53
Figure 22: Status digital outputs .................................................................................... 54
Figure 23: Status digital inputs ...................................................................................... 54
Figure 24: UPS Status ................................................................................................... 55
Figure 25: Status/Control ............................................................................................... 56
Figure 26: Password list ................................................................................................ 57
Figure 27: Date / time .................................................................................................... 58
Figure 28: Message display ........................................................................................... 59
Figure 29: Message archive with printer function. ......................................................... 60
Figure 30: CPU diagnosis cache ................................................................................... 61
Figure 31: Change log ................................................................................................... 62
Figure 32: Data record processing ................................................................................ 63
Figure 33: Program information ..................................................................................... 66
Figure 34: Faults of electrical axis ................................................................................. 67
Figure 35: Reference point location ............................................................................... 72
74

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WALTEC

WALTEC Maschinen GmbH, Kronacher Str. 2a, D-96352 Wilhelmsthal, 07/2015

Operating Manual - Electronic Control Feeder and Shears,z-e.doc

Notes to the conformity declaration based on the regulation

Note: We reserve the right to make changes based on technical advancement.

Operating Manual - Electronic Control Feeder and Shears,z-e.doc

Telefon: +49 (0)9260 99 01-0

FUNDAMENTAL SAFETY INSTRUCTIONS

Warnings and symbols

Basic operation and designated use of the machine/plant

Selection and qualification of personnel - Basic responsibilities

1.5 Safety instructions governing specific operational phases

Mobile machinery and equipment

ELECTRONIC LOGIC CONTROLLER

STRUCTURE OF CONTROL CABINET

DESCRIPTION OF THE FUNCTIONS IN THE CONTROL CABINET

4.1 Screen and keyboard

Operating Manual - Electronic Control Feeder and Shears,z-e.doc

Screen Description: STATUS CU320

SWITCHING MACHINE ON AND MANUAL OPERATION

INITIAL POSITION OF THE MACHINE AND AUTOMATIC OPERATION

Engagement of automatic mode

Settings in automatic mode

Shutting off the machine

MALFUNCTION IN AUTOMATIC MODE AND EMERGENCY-OFF

MALFUNCTIONS AND THEIR RECTIFICATION S7-300

Overall Reset of the control S7-300

ADJUSTMENTS WHEN CHANGING AN AXES DRIVE

Necessity for Locating the Reference Point

Locating the Machine Reference Point

Calculating the Reference Point Displacement

Operating Manual - Electronic Control Feeder and Shears,z-e.doc

Foreword to the operating instructions

Operating Manual - Electronic Control Feeder and Shears,z-e.doc

Fundamental safety instructions

1.1 Warnings and symbols

Reference (refers to special information on how to use the

Attention (refers to special information and/or orders and prohibitions

1.2 Basic operation and designated use of the machine/plant

Operating Manual - Electronic Control Feeder and Shears,z-e.doc

1.3 Organisational measures

Operating Manual - Electronic Control Feeder and Shears,z-e.doc

Operating Manual - Electronic Control Feeder and Shears,z-e.doc

Operating Manual - Electronic Control Feeder and Shears,z-e.doc

1.4 Selection and qualification of personnel - Basic responsibilities

Operating Manual - Electronic Control Feeder and Shears,z-e.doc

1.5 Safety instructions governing specific operational phases

Operating Manual - Electronic Control Feeder and Shears,z-e.doc

Operating Manual - Electronic Control Feeder and Shears,z-e.doc

1.6 Warning of special dangers

Operating Manual - Electronic Control Feeder and Shears,z-e.doc

Gas, dust, steam and smoke

Hydraulic and pneumatic equipment

Operating Manual - Electronic Control Feeder and Shears,z-e.doc

Oil, grease and other chemical substances

1.7 Mobile machinery and equipment

Operating Manual - Electronic Control Feeder and Shears,z-e.doc

Operating Manual - Electronic Control Feeder and Shears,z-e.doc

Electronic logic controller

Structure of control cabinet