AirSpeed HC VERSA Operator Manual - Pregistechportal.pregis.com/Portals/6/Manuals/HC/AirSpeed HC...

11-01-2010

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AirSpeed HC VERSA

Operator Manual

11-01-2010


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11-01-2010


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SECTION INSTRUCTION NUMBER

1 SAFETY

OPERATING SAFETY 1-1 SAFETY ALERTS 1-2

2 OPERATION

INTRODUCTION 2-1 OPERATOR CONTROLS 2-2 MANAGEMENT INTERFACE SCREENS 2-3 OPERATING PROCEDURE 2-4

3 MAINTENANCE

DRIVE BELT REPLACEMENT 3-1

SEALING DRUM REPLACEMENT 3-2

HEIGHT ADJUSTMENT 3-3

MAINTENANCE SCHEDULE 3-4

4 TROUBLESHOOTING

TROUBLESHOOTING 4-1

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OPERATING SAFETY HC VERSA AIR CUSHION MACHINE

Operator safety and the safety of others in the

work area depend on the operator using

common sense, good judgment and reasonable

care while operating the machine. The Safety,

Operation and Maintenance manual, and

warning labels affixed to the machine, provide

notification of specific potential hazards.

NOTE: Refer to the Safety Alerts instruction for

additional safety-related information.

Safety The following instructions are only a

guideline and should be considered a

supplement to your plant's comprehensive

safety program. Your company’s policy

supersedes these guidelines if at any time

the two contradict each other.

1. Read and understand the manual. If

after reading the manual you have questions,

get answers before working with the machine.

2. Read and understand all of the danger,

warning and caution statements in the manual

and on the signs attached to the equipment.

3. Never deface or remove factory

installed warning decals. If a decal ever

becomes lost, damaged or illegible, report this

condition to a supervisor and obtain a

replacement decal.

4. Keep the work area clean and

uncluttered. Walking surfaces should always be

free of packing material and debris to prevent a

slipping or tripping hazard.

5. Ensure that all covers, guards and other

safety devices are in place. Never defeat a

safety device for any reason.

6. Follow the manufacturer's

recommended startup procedure.

7. Never leave the equipment unattended

while operating. Shut the machine off if you

must leave the work area.

8. Keep body parts and clothing away

from moving components. Never reach into the

machine for any reason while it is in motion.

9. Understand what will happen when you

operate the various controls.

10. Understand the proper web path and

the safe method for threading the web.

11. Learn the safe procedure for clearing

the machine of web wraps or jams.

12. Exercise extreme care whenever it is

required to inspect or adjust the machine while

it is in motion. NEVER reach into the machine

for any reason while it is in motion.

13. Understand which adjustments are

operator adjustments; contact a maintenance

person to make all other adjustments.

14. Never operate or work around

equipment if you are under the influence of

alcohol, drugs or medications that can make

you less alert or affect your judgment.

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SAFETY ALERTS HC VERSA AIR CUSHION MACHINE

Operator safety and the safety of others in the

work area depend on the operator using

common sense, good judgment and reasonable

care while operating the machine. The Safety,

Operation and Maintenance manual, and

warning labels affixed to the machine, provide

notification of specific potential hazards.

Safety signs are used to alert operating and

maintenance personnel to potential hazards.

The machine manual also calls attention to

potential hazards with statements describing

the hazard. Both the safety signs on the

machine and the warnings in the manual use

signal words to identify the seriousness of the

potential hazard. These signal words are

Danger, Warning and Caution.

The meanings of the signal words and the level

of potential hazards they represent must be

clearly understood before attempting to

operate or maintain the machine. If, at any

time, a safety sign on the machine becomes

lost, damaged or illegible, contact Pregis to

order replacement signs at no charge.

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INTRODUCTION HC VERSA AIR CUSHION MACHINE

Introduction

The Pregis HC VERSA (Figure 1) produces panels

of air-filled packing cushions in any quantity, as

needed. The ability to create packing cushions

on demand saves storage space and reduces

packaging material waste.

Film rolls up to 30" (609mm) wide by 9"

(229mm) diameter on 3" (76mm) ID paper

cores. Packing cushions are created in panels of

individual cushions.

A string of panels can be torn apart at

perforations cut between each panel. Cushions

are created at a constant rate of up to 75 feet

per minute (fpm) of film feed.

Figure 1

HC VERSA

DO NOT OPERATE WITH GUARDS REMOVED!

Operation

The film web is a continuous tube with a seal

pre-applied across the web every 1.88". A

perforation has also been pre-made every 15".

The cross seals end exactly 0.533" from one

sealed edge of the film. This creates an

unsealed gap, in the film direction, along that

edge of the film.

The roll of film is loaded into the film roller with

the air pipe channel edge towards the inside.

See Figure 2.

Figure 2

From the film roller, the film is routed around

an idler roller that changes its direction to route

it into the sealing section. A Slip Clutch on the

Film Roller provides a braking action on the

parent roll to create a slight tension in the film

between the parent roll and drive belts nip. The

braking also prevents the roll from continuing

to spin when the machine is stopped. See

Figures 2 and 3.

Figure 3

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A proximity sensor is mounted at the Infeed of

the pulley system. The sensor acts as a counter

for detecting and measuring film feed. This

value is used to run the machine for a given

distance of film, and then automatically stop.

The film counter also acts as a "Film Out" or

"Web Break" detector. If the PLC sees the

counter stop, it then stops the machine and

displays a message.

Upper and lower drive belts are each routed

around a tensioner flanged guide roller, idlers,

the sealing drum and the drive pulley. The belts

follow the same path for about half their

lengths, with surface contact providing a nip

section that captures the film.

The upper belt is directly driven by a stepper

motor, through a coupling. The pressure

between the two belts is sufficient to drive the

film, contain the air in the cushions, hold the

film against the sealing drum surface, drive the

drum, and drive the lower belt.

An external air pump generates the air pressure

used to inflate the cushions. Just upstream of

the drive belts initial nip point, air is injected

into the cushions through an outlet slot in the

air pipe. The edge of the inflating cushion is

then captured between the upper and lower

belts, which contain the cushion air while

providing pressure over the sealing drum. See

Figure 4.

Infrared

Temp

Sensor

Jog

Button

Sealing

Drum

Air Pipe

Upper

Belt

Lower

Belt Slitter

Blade

Drive

Pulley

Tensioner

Guide

Tensioner

Guide

DO NOT

OPERATE WITH

COVER OPEN!!

Figure 4

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Stepper

Motor Power

Supply

Air Valve

Main Air

Supply Hose

DO NOT

OPERATE WITH

COVER OPEN!!

Air Pump

Figure 5

Figure 5a

Figure 6

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OPERATOR CONTROLS FOR THE PREGIS HC VERSA

1) Operator Interface Touch screen

Used to monitor, select, and adjust the

operating parameters

2) Input Interface Port

Used to connect to secondary

equipment

3) Power Switch

Used to turn power on and off

4) Compressor Power Cable

Used to supply power to the stand

alone Compressor

Figure 7

Figure 8

(1)

(2)

(3)

(4)

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OPERATOR CONTROLS

HC VERSA

AIR CUSHION MACHINE

Startup Screen

When the HC Versa up, it will first display a

startup screen, which will list the software

family as well as versions of the PLC

(controller) and HMI (display) programs. In

startup, the display background will be

green and will not flash.

Main Screen Simple (Ready to Run)

This screen allows the operator to Start the

Machine and Jog the Machine.

Machine will run in current selected mode.

Main Screen Complex (Ready to Run)

This screen allows the operator to Start the

Machine, Jog the Machine, Set Heat Settings

and Select Run Mode.

Machine will run in current selected mode.

Start: Press this button to initiate a start

signal and start running the selected

Run Mode in Automatic. In Specified

Distance Mode and Continuous Run

Mode this button will turn “blank”

while running. In Basket Fill Mode this

button will turn to the Pause Indicator.

Jog: Press and Hold this button when

the machine is idle, to jog the Belts

forward. When the machine is running

in any of the Run Modes this button will

turn to the Stop Button indicator.

Pause – Only in Basket Fill Mode is this

button available. Press this button to

Pause the cycle. Unlike the stop button,

pressing “Start” will resume where you

left off, running the remaining distance.

Stop – Press this button initiate a

controlled stop. Distance ran will be

reset, and the Machine will wait in an

idle state for another Start Signal.

Start Jog

Jog

Start

Current

Mode

Setup

Distance

Selector

Air

Adjust

Favorites

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Specified Distance Mode – Upon Start

signal, the machine runs for the

distance specified, and then waits for

another start signal.

Fill Basket Mode – Upon Start signal

the machine will enter a pause mode,

where it will wait until the basket fill

sensor is clear. The basket fill sensor

must be plugged in and not blocked for

the machine to run.

Continuous Run Mode – Upon Start

signal the machine will run continuously

until the stop button is pressed.

Pressing this indicator will toggle

between modes.

Setup: Press this button to access the

Setup Screen where Heat Seal,

Complexity, and Advanced Settings

screens may be reached.

Air Adjust: Press this button to access

the Air Adjust Screen where the amount

Air in the cushions can be adjusted.

Favorites: Press this button to access

the Favorites Screen where current

Recipes may be either saved as a

Favorite or Selected to Run.

Distance Selection: This indicator

will show the distance the machine

is set to run. Pressing this indicator

will bring up the Distance

Adjustment Screen where the

Length of run can be adjusted.

Units will be Metric or Imperial

depending which is selected in the

Advanced Setup.

Distance Adjustment Screen

This Screen is where the length of run can

be specified. Limits for the max and min of

this setting are password protected in the

Advanced Settings Menu.

Distance Selection: This indicator will

show the distance the machine is set to

run. Units will be Metric or Imperial

depending which is selected in the

Advanced Setup.

DISTANCE

SELECTION

RETURN/ENTER

DECREMENT

DISTANCE

INCREMENT

DISTANCE

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Increment Distance: Pressing any of

these three buttons will increment the

distance to run. Each button controls

the Distance Selection position directly

above it (ie increment by 1’s, 10’s or

100’s), depending how fast the user

desires to increment.

Decrement Distance: Pressing any of

these three buttons will decrement the

distance to run. Each button controls

the Distance Selection position directly

above it (ie decrement by 1’s, 10’s or

100’s), depending how fast the user

desires to decrement.

Return/Enter: Pressing this button will

store these values as the new distance

to run. It will also return the user to the

Main Screen.

Favorites Screen

This Screen is where the currently selected

speed, air and temperature values may be

saved as a favorite, or where previously

saved favorites may be quickly selected to

run. These can be thought of as Three

Custom Recipies.

Favorite Recipe #1: Pressing this button

will select this slot, and allow the user

to save the current speed, air and temp

values as the new #1 Favorite, or Run

the stored #1 Favorite.











Save Selected: Pressing this button will

take the user to the Password Screen,

after entering the password they will be

immediately taken to the Save Favorite

Screen where the current speed, air and

temp values will be become the new

favorite for the selected Favorite Slot.

Run Selected: Pressing this button will

load the stored favorite settings, for the

selected Favorite.

FAVORITE

RECIPE #1

FAVORITE

RECIPE #2

FAVORITE

RECIPE #3

SAVE

SELECTED

RUN

SELECTED

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Air Adjust Screen

This screen allows the operator to navigate

to the Complexity, Password, Recipe, or

Heat Seal Screens.

Increment Air Flow: Pressing this

button will increase the Amount of Air

in each cushion. Scale is from 0 to

100% of the Min and Max Set Values,

which are declared in the Advanced

Settings.

Decrement Air Flow: Pressing this

button will increase the Amount of Air

in each cushion. Scale is from 0 to

100% of the Min and Max Set Values,

which are declared in the Advanced

Settings.














store these values as the new distance

to run. It will also return the user to the

Main Screen.

Setup Screen

This screen allows the operator to navigate

to the Complexity, Password, Recipe, or

Heat Seal Screens.

Heat Seal Temperature: Pressing this

button will open up the Temperature

Screen where adjustments to the Heat

Drum Temperature can be made.

Advanced Settings: Pressing this button

will bring up the Password Screen.

RETURN/ENTER

ADVANCED

SETTINGS

HEAT SEAL

TEMPERATURE

COMPLEXITY

MENU

RECIPE

MENU

INCREMENT

AIR FLOW

DECREMENT

AIR FLOW Start

Jog

RETURN/ENTER

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Complexity Menu: Pressing this button

will open up the Complexity Menu

Screen where the User may select

which main screen is active, the

Complex or the Simple.

Recipe Menu: Pressing this button will

take the user to the Password Screen,

then directly to the Current Recipe

Screen, where they may see which

Material Type is running on the

Machine.


store the current air settings as the

amount of air to run. It will also return

the user to the settings screen.

Temperature Screen

This Screen is where the temperature of the

Heat Seal Drum can be adjusted. Limits for

the max and min of this setting are

password protected in the Advanced

Settings Menu.

Actual Temperature: This indicator will

show the current temperature of the

Heat Drum. Units will be in either

Celsius or Fahrenheit depending which

is selected in the Advanced Setup.

Increment Temperature: Press this

button to increase the temperature

set point of the Heat Drum which

Seals the Cushions. The maximum

value is set in the password

protected, Advanced Settings

Menu.






Temperature Set point: This

indicator will show the temperature

set point of the Heat Drum. Units

will be in either Celsius or

Fahrenheit depending which is

selected in the Advanced Setup.


store the current air settings as the

amount of air to run. It will also return

the user to the settings screen.

RETURN/ENTER

DECREMENT

TEMPERATURE

TEMPERATURE

SETPOINT

START

JOG

INCREMENT

TEMPERATURE

ACTUAL

TEMPERATURE

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Decrement Temperature: Press this

button to decrease the temperature

set point of the Heat Drum which

Seals the Cushions. The minimum

value is set in the password

protected, Advanced Settings

Menu.

Complexity Menu Screen

This screen allows the user to select a

complexity level for the man screen.


return the user to the Main Screen.

Main Screen Simple: Pressing this

button will give the user the Simple

Main Screen which only has a Start and

Jog Button. Pressing this button will

also toggle the indicator.

Main Screen Complex: Pressing this

button will give the user the more

Complex Main Screen which allows the

user to adjust which run mode is

selected, as well as adjust the Heat

Settings. Pressing this button will also

toggle the indicator.

Current Recipe Screen

This screen shows the user which

combination of material is currently

selected. A favorite will show as a Custom

Recipe.

Change Recipe: Pressing this button will

take the user to the Cell Size Selection

Screen where they may select which

size material they would like to run.

MAIN SCREEN

COMPLEX

MAIN SCREEN

SIMPLE RETURN/ENTER

CHANGE RECIPE RETURN/PREVIOUS

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Return/Previous: Pressing this button

will take the user back to the Previous

Screen.

Recipe Cell Size Screen

This screen allows the user to Scroll through

the possible Cell Sizes, Small, Medium or

Large.

Cell Size: Pressing this button will scroll

through the available Cell Sizes

Enter Next: Pressing this button will

take the user to the Material width

Selection Screen where they may select

which width material they would like to

run.



Screen.

Recipe Material Width Screen


the possible Material Widths, Standard,

Ultra, or Wide Web.

Material Width: Pressing this button

will scroll through the available Material

Widths.


take the user to the Material Grade


which grade material they would like to

run.



Screen.

Recipe Material Grade Screen


the possible Material Grades, Standard

(Clear), Renew (Green), Flex or Heavy Duty.

CELL SIZE

ENTER/NEXT RETURN/PREVIOUS

MATERIAL

WIDTH


MATERIAL

GRADE


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Material Grade: Pressing this button

will scroll through the available Material

Grades.


take the user to the Material Grade


which grade material they would like to

run.



Screen.

Recipe Confirmation Screen

This screen allows the user to review their

material selection before running it.

Run Recipe: Pressing this button will

Load the Recipe settings.



Screen.

Save Favorites Screen


the possible Material Grades, Standard

(Clear), Renew (Green), Flex or Heavy Duty.

Save: Pressing this button will save the

Current Recipe as the Selected

Favorites.

Cancel: Pressing this button will return

the User to the favorites screen without

saving.

Password Screen

This Screen allows user to enter password to

gain access to advanced Settings and other

setup/debug tools.

PASSWORD

INDICATOR

INCREMENT

PASSWORD

DECREMENT

PASSWORD RETURN/ENTER

SAVE CANCEL

Run Recipe RETURN/PREVIOUS

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Password Indicator: This indicator will

show the current number in each slot

that has been scrolled to, using the

increment and decrement buttons

beneath. Range is 0 to 9 for each of the

three indicators.

Increment Password: Pressing any

of these three buttons will

increment the password indicator

above. Each button controls the

Password Indicator position directly

above it.

Decrement Password: Pressing any

of these three buttons will

decrement the password indicator

above. Each button controls the

Password Indicator position directly

above it.


submit the Password. If the password is

incorrect or blank, the user will be

returned to the previous screen. If the

password is correct the user will be

taken to the Advanced Settings Screen.

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ADVANCED CONTROLS

HC APPLIANCE

AIR CUSHION MACHINE

Advanced Setup Screen

This Screen allows user to navigate to the

Advanced Settings Menu. This screen can only

be accessed if the user provides the correct

Password.

Settings: This button will bring up the

Settings Menu, which will allow the user

to navigate to different System Settings.

Set Points: This button will bring up the

Set Points Menu, which will allow the

user to navigate to screens which allow

the defining of different set points.

Return to Main: This button will take

the User back to the Main Idle Screen.

After pressing this button the user will

be required to re-log in if they wish to

access the Advanced Settings again.

Service: This button will bring the user

to the Service Menu, which has

different tools designed for Service

personnel to allow debugging and ease

of setup.

Settings Screen

This Screen allows user to define various system

settings. This screen can only be accessed if the

user provides the correct Password.

Mode and Defaults: This button will

take the User to the Mode and Defaults

Screen where various system settings

can be defined and system can be reset

to factory defaults.

Startup Settings: This button will take

the User to the Screen where they can

adjust the Startup Solenoid Settings.

Pid Settings: This button will take the

User to the Pid Setting Screen where

adjustments to the Pid Loop function

may be made.

SETTINGS

SETPOINTS

SERVICE RETURN TO MAIN

MODE AND

DEFAULTS

STARTUP

SETTINGS

PID

SETTINGS RETURN TO SETUP

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Return to Setup: This button will return

the user to the previous screen.

Mode and Default Screen


settings, and reset to factory defaults. This

screen can only be accessed if the user provides

the correct Password.

Unit Select: This button allows the user

to select if Standard Units or Metric

Units are used for any distance and

temperature indicators that an operator

may use.

Test Mode: This function will allow the

machine to ignore the tow Roller sensor

and run without product.

Lockout: This function will lock in the

current settings, and block the ability to

change any settings that a normal

operator would not need to adjust.

Return to Settings: This button will

return the user to the previous screen.

Restore Defaults: This function will

reset all values to the factory default

settings.

Mode and Default Screen


settings, and reset to factory defaults. This

screen can only be accessed if the user provides

the correct Password.

On Delay Increment: This function will

Increase the Startup Solenoids on time

by 1/100th

of a second.

On Delay Decrement: This function will

Decrease the Startup Solenoids on time

by 1/100th of a second.

UNIT

SELECT

TEST

MODE

LOCKOUT RESTORE RETURN TO SETTINGS

ON DELAY

INCREMENT

OFF DELAY

INCREMENT PULSE COUNT

DECREMENT

ON DELAY

DECREMENT

PULSE COUNT

INCREMENT OFF DELAY

DECREMENT

RETURN TO SETTINGS

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Off Delay Increment: This function will

Increase the Startup Solenoids off time

by 1/100th

of a second.

Off Delay Decrement: This function will

Decrease the Startup Solenoids off time

by 1/100th

of a second.

Pulse Count Increment: This function

will Increase the number of Pulse

Counts by 1.

Pulse Count Decrement: This function

will Decrease the number of Pulse

Counts by 1.

Return to Settings: This button will


PID Settings Screen

This Screen allows user to make adjustments to

the Pid Loop function.

Idle: This button will take the user

to the PID settings for when the

Machine is in an Idle State.

Transient: This button will take the

user to the PID settings for when

the Machine is in a Transition State.

Transient: This button will take the

user to the PID settings for when

the Machine is in a Steady State.

PID Idle Screen

This Screen allows user to make

adjustments to the Pid Loop function, when

the machine is in an Idle State. Transient

and Steady State Screens are the same.

Proportional: Proportional Gain –

Reduces a large part of the overall error

(ie where the controller is vs where the

controller needs to be)

Integral: Integral Gain – Reduces the

final error in a system.

IDLE

TRANSIENT

STEADY

STATE RETURN TO SETTINGS

PROPORTIONAL

INTEGRAL

DERIVATIVE

HIGH LIMIT

RETURN TO Pid

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Derivative: Derivative Gain –

Counteracts I and P when the signal

changes quickly, helps reduce overshoot

and ringing in a system.

High Limit: Maximum controlled output

of the system.

Return to PID: This button will return


Setpoints Menu

This Screen allows user to adjust Feed and Limit

Setpoints

Feed Set Points: This button will take a

user to a screen where they can adjust

different settings related to the direct

feed of product.

Limit Set Points: This button will take a


different minimum and maximum

values of the machines various set

points.



Feed Set Points Screen

This Screen allows user to navigate to screens

which will allow defining of various system set

points.

Increment Speed: This button will allow

the User to increase the speed set point

of the machine.

Decrement Speed: This button will

allow the User to decrease the speed

setpoint of the machine.

Increment Heat Delay: This button will

allow the User to increase the amount

of the time allowed for the Heater to

reach its sealing temperature.

FEED

SET POINTS

LIMIT

SET POINTS

RETURN TO SETUP

INCREMENT

SPEED

DECREMENT

SPEED

INCREMENT

HEAT DELAY

DECREMENT

HEAT DELAY

RETURN TO SETPOINTS

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Decrement Heat Delay: This button will

allow the User to decrease the amount

of the time allowed for the Heater to

reach its sealing temperature. Setting

this value too low may result in

unnecessary faults.

Limit Set Points Screen

This Screen allows user to navigate to screens

which will allow defining of various system set

points.

Heat Limits: This button will take a user

to a screen where they can set the

Minimum and Maximum temperature

limits that the operator is allowed to

adjust between.

Prefill Limits: This button will take a


the Amount of Material to Pre-Run in

Winder Mode. BUTTON ONLY

FUNCTIONS IN WINDER MODE.

Return to Setpoints: This button will


Heat Limits Screen

This Screen allows the user to adjust the

minimum and maximum allowable temperature

setpoints that the operator may select.

Increment Low Limit: This button will

allow the User to increase the minimum

allowable temperature setpoint that the

operator is allowed to adjust to.

Decrement Low Limit: This button will

allow the User to decrease the

minimum allowable temperature

setpoint that the operator is allowed to

adjust to.

Increment High Limit: This button will

allow the User to increase the

maximum allowable temperature


adjust to.

HEAT LIMITS

RETURN TO SETPOINTS

PREFILL

LIMITS

INCREMENT

LOW LIMIT

INCREMENT

HIGH LIMIT

DECREMENT

HIGH LIMIT

DECREMENT

LOW LIMIT RETURN

TO LIMITS

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Decrement High Limit: This button will

allow the User to decrease the

maximum allowable temperature


adjust to.

Return to Limits: This button will


Prefill Run Distance Screen

This Screen is only available in Winder Mode

when the Winder is plugged in, it allows the

User to adjust the amount of material that is

ran out before the winder starts running.

Decrement Distance: This button will

allow the User to decrease the amount

of material that is run before the

Winder Starts automatically.

Increment Distance: This button will

allow the User to increase the amount

of material that is run before the

Winder Starts automatically.

Return to Limits: This button will


Service Screen

This Screen has different tools designed for

Service personnel; allows debugging and ease

of setup.

View I/O: This button takes user to a

screen where they may view real world

inputs to the PLC and toggle select

outputs.

Break in Heater: This button takes user

to a screen where they may set

parameters for running just the heater

drum in order to break it in and

condition it for optimal performance.

Debug: This button takes user to a

screen where they view the data of

specific PLC bits or run tests. This tool is

most useful in conjunction with

manufacturer phone support.



INCREMENT

DISTANCE

DECREMENT

DISTANCE

RETURN

TO LIMITS

VIEW I/O

BREAK-IN

HEATER

DEBUG

RETURN TO SETUP

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View I/O Screen

This Screen allows the user to select either the

PLC Inputs screen or PLC Output screen for

viewing.

View Inputs: This button will take the

user to a screen where they may view

the PLC Inputs.

View Outputs: This button will take the

user to a screen where they may view

the PLC Outputs.

Return to Service: This button will


View Inputs Screen

This Screen allows the user to see all of the

available PLC Inputs and their real world states.

Film Jam: This Indicator is for the Film

Jam Proximity Switch. It will show high

(illuminated) if the sensor is blocked.

Basket Fill: If Applicable, this Indicator

is for the Basket Fill Ultra Sonic Sensor.

The higher the value the closer the

object is to the sensor.

Temp Input: This Indicator is for the

Heat Drum Temperature Infrared

Sensor. It will show a value in Millivolts.

The higher this value, then the higher

the temperature, of the Heat Drum.

Foot Switch: If Applicable, this

Indicator is for the Foot Switch. The

input will be show High (Illuminated) if

the Footswitch is pressed.

Return to I/O: This button will return


View Outputs Screen

This Screen allows the user to toggle the Real

World PLC Outputs.

VIEW INPUTS

VIEW OUTPUTS

RETURN TO SERVICE

FILM JAM

BASKET FILL

TEMP INPUT

FOOT SWITCH RETURN TO I/O

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Air Enable: Press this button to turn on

the Air Compressor

Jog Motors: Press and hold this button

to jog the motor.

Valve Enable: Press this button to turn

on the Valve.

Return to I/O: This button will return


Seal Drum Break-In Screen

This Screen allows the user run just the heater

drum in order to break it in and condition it for

optimal performance.

Time Left: This Indicator shows the

time remaining in the current Seal Drum

Break In cycle. Pressing this indicator

will bring up the Seal Drum Adjustment

Screen where the amount of time for

the cycle may be adjusted.

Start: Pressing this button will Start the

Seal Drum Break-In Cycle.

Stop: Pressing this button will Stop the

Seal Drum Break-In Process. This will

also reset the Time Remaining indicator.



Seal Drum Break in Adjustment Screen

This Screen allows the user to specify the

amount of time to run the Seal Drum Break in

Cycle

Set Time: Press this indicator to bring

up a data entry box that will allow you

to specify the amount of time to run the

Seal Drum Break-In Cycle.

Return to Break-In: This button will


STOP

START TIME LEFT RETURN TO SERVICE

SET TIME

RETURN TO BREAK-IN

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Debug Screen: This screen allows user to view

the data of specific PLC bits or run tests. This

tool is most useful in conjunction with

manufacturer phone support.

Test Screen: This button will take the

user to the Testing Screen where a test

cycle can be run on the machine.

Debug Screen: This button will take the

user to the Debug Screen where

individual PLC bits and data registers

can be monitored through the HMI.



Test Screen

This Screen allows the user to specify the

amount of time to run the test cycle.

Decrement On Time: This button will

decrease the amount of time the Test

Cycle is in the On or running state.

Increment On Time: This button will

increase the amount of time the Test

Cycle is in the On or running state.

Decrement Off Time: This button will

decrease the amount of time the Test

Cycle is in the Off or stopped state.

Increment Off Time: This button will

increase the amount of time the Test

Cycle is in the Off or stopped state.

Test: This button will toggle the test

cycle. The test cycle will continue the

machine between on and off states,

stay in each state for the amounts of on

and off time, until the test button is

pressed again or until the user navigates

away from this screen.

Return to Debug: This button will


TEST SCREEN

DEBUG SCREEN

RETURN TO SERVICE

DECREMENT

ON TIME

DECREMENT

OFF TIME

INCREMENT

ON TIME

INCREMENT

OFF TIME

TEST

RETURN TO DEBUG

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Debug Screen

This Screen allows the user to select up to five

different PLC bits or Data registers and view

their current state/value in the table shown.

Data Type: This button indicates the

type of data that is being looked at.

Pressing this button will take the user to

the Data Type Selection screen where

there is a list of possible data types.

Data Address: This button indicates the

Data Address that is selected. Pressing

this button will bring up a key pad that

allows the user to enter in the address

of the desired bit or data register.

Value In PLC: This indicator cell shows

the value of the selected Bit or Data

Register that is currently stored in the

PLC.

Return: This button will return the user

to the previous screen.

Data Type Selection Screen

This Screen allows the user to select which type

of data to view in the Debug Screen.

Input: This is an Input bit that is tied to

a real world Input of the PLC. These bits

will only turn on if there is a signal

applied at the real world input terminal

of the PLC.

Output: This is an Output bit that is tied

to a real world output of the PLC.

Internal Register: Internal Register is a

value that is stored in the PLC, and

activated by the Logic within the PLC

Code.

VALUE IN

PLC

RETURN DATA

ADDRESS

DATA TYPE

INTERNAL

REGISTER

ELASPED

VALUE

OUTPUT

SET

VALUE

INPUT

DATA TABLE

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Data Table: This is a register that

usually contains a real world value or a

number.

Set Value: This applies to Timers and

Counters and is the target value of the

timer or counter. Once the Elapsed

Value is equal to the Set Value the timer

or counter will turn on the done bit.

Elapsed Value: This applies to Timers

and Counters and is the amount of

timer or number of counts that have

passed. It can be thought of as the

“current value” of a timer or counter.

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TROUBLESHOOTING

FOR THE PREGIS HC ULTRA

Error Screen Cause Solution

Temperature Too High

Temperature Sensor is

reading a temperature above

the set limits. Verify Sensor

Alignment and that the Heat

Drum is functioning properly.

Temperature Too Low Temperature Sensor is

reading a temperature below

the set limits. Verify Sensor

Alignment and that the Heat

Drum is functioning properly.

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Temperature Timeout Temperature Sensor is

reading a temperature, but it

is taking too long for the Heat

Drum to reach the

Temperature Set point. Verify

Sensor Alignment and that the

Heat Drum is functioning

properly.

.

Film Jam/No Film

Film is not passing through

the Tow roller because of a

jam or there is no more

product.

Verify that the sensor on the

Tow Roller is functioning

correctly and switching state

when the set screws on the

Rollers pass the face of the

sensor.

Verify the Film is causing the

Tow Rollers to rotate.

PLC Operational Error

Un-Expected operation in PLC.

Reset error and try operation

again, if problem persists

contact Technical Support.

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Recipe Error Error loading current Recipe.

Try repowering machine and

reloading recipe if Problem

persists contact Technical

Support.

Guide Block In Position Error The Guide Block is not in

Position.

Ensure Guide Block is secured

in position. Verify Prox

mounting and wiring.

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NOTES:

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