Chapter 5 - OPERATOR INSTRUCTIONS

Serial n° 655/09

Ensure that the operations described in the following Chapter 5 "OPERATOR

INSTRUCTIONS", are carried out by MACHINEMEN, instructed in the use of
guards: how to open and replace them and free themselves if trapped.
For the classification of MACHINEMAN, see point 15 in the paragraph on
"GENERAL SAFETY WARNINGS", page III.

5.1 - MACHINE CONTROL POSITIONS

Machine controls are concentrated in the control panels.
Other controls are installed in the areas where manual operations are carried out.

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5.1.1 Electric cutout box

The main disconnecting switch is installed in the electric cutout box.

This switch cuts power to the whole system as well as the panel itself.
The switch has a handle with padlock.
The cutout box has a warning hooter and lamp to signal machine start-up.

5.1.2 Buttons, selectors and controls

Buttons located below the control panel.

1) “EMERGENCY RESET” button: used to rearm the safety interlock switches on the
access doors after a transparent guard has been opened. This button must be
held down for at least one second.
2) “START” button: starts the motors and allows the automatic production cycle to
start.
3) “STOP IN PHASE” button: shuts down the motors.
4) Key-operated SAFETIES EXCLUSION ON/OFF switch
- In the ON position, this switch disables certain safety devices.
- In the OFF position, this switch enables these safety devices.

1 2 3 4

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Pushbuttons located on the right side of the electrical cabinet.

5 6

5) Signal lamp RELEASING REEL WORKING: this lamp (which is always on) indicates
when the safety device on the electric panel doors are excluded. Check, when the
lamp is off, if the safety device have been disconnected on the electric panel or, in
extremely rare cases, if the lamp has broken. Personnel in charge of the system may
work with the panel doors open (for carrying out maintenance and assuming full
responsibility), by setting the safety micro-switches located on each door to position
3.
- pos. 1: doors closed
- pos. 2: doors open
- pos. 3: doors open and electric box receiving power (for maintenance purposes).

1 2 3

6) Signal lamp RELEASING REEL CIRCUIT ON: this lamp (which is always on)
indicates any defect in the electric panel doors safety device cut-out circuit. In the
event of an unlit lamp, breakdown may not necessarily be linked to the releasing reel
but may be caused by another component of the safety circuit.

WARNING: The tripping reel, also known as the cut-out or remote release reel,
actually opens the switches. As it must be supplied with power to carry out this
function, it cannot work if connections are broken or in a blackout. As this is
unacceptable in an emergency situation we must either use a totally fail-save
device, like a minimal tension reel, or a device for monitoring the releasing reel
circuit to warn of any inefficiency. As the tripping reel is not a fail-safe device it
is often associated with a relay device to control the switch’s opening circuit, in
practise these signal any interruption to the circuit running from the release
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device to the coil, more sophisticated device can be used to transform, for
engineering reasons, the tripping coil into a totally fail-safe release device. This
solution is only legal when accompanied by a signal light to indicate circuit
functioning. If the lamp is off then that the reels supply circuit has been
interrupted. As this type of signal is not always clearly understood, we
recommend only using a tripping coil in systems with trained personnel present.
In any case the latter solution using a control circuit is considered less
trustworthy than the former.

Connection located below the control panel.

7) PRO-FACE USB CONNECTION: this connection is reserved for Opem technicians.

It is used to connect a PC to the control panel.

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5.2 - CONTROL PANEL

On starting up the machine, the panel will display an introductory page where the operator
can select the language for dialogue by pressing the appropriate national flag icon.
The following instructions are provided for machine technicians and system heads. For
this reason if the person in charge believes modifications are needed to data pre-set by
Opem technicians, he does so under his own initiative and is responsible for any
programming errors which might damage production or the system.
Some data is protected by passwords to prevent the system being inadvertently damaged
by programming errors.

IMPORTANT

The different pages of the control panel are protected by password levels based on
the functions they permit to be carried out.
There are 2 basic set password levels with one exclusively reserved for Opem
personnel.

Protection
Function
level
Reserved for machine operators. Gives access to main page and only
Operator displays some of the pages used for carrying out data alterations or manual
operations.
Reserved for Opem personnel. Permits carrying out any operation
OPEM
whatsoever to the system.

S/N 655/09
PASSWORD: 100

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5.2.1 Main page

Follows the introductory page; it automatically displays:

1) the current date and time

2) the number of the current program
3) the operating speed and position of both the CL100/S and Monopack encoders
4) some signal lamps and a series of keys are found on every page, their functions are
described below.

KEY DESCRIPTION
This is a signal lamp. As the product sensor on the
dosing unit is hidden from the operator’s sight, this
lamp reports its state on the panel. A flashing light
indicates that the sensor is detecting product in the
dosing unit. In practice the lamp reproduces auger
motor operations.
This is a signal lamp. As the constant feed sensor on
the dosing unit is hidden from the operator’s sight,
this lamp reports its state on the panel. A flashing
light indicates that the horizontal constant feed auger
is supplying product to the dosing unit.

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Use this switch to release the Monopack packaging machine film

reel brake. Use when changing reels. Must not be included during
work cycle

Use this switch to connect or cut out continuos pump operations

when the machine is at a standstill. Must be connected during the
machine cycle.

This selector locks the film roll in the area where the film must be
spliced. It is used when the roll is changed and must not be
pressed during production.

When pressed with the machine stopped, this button releases the
film on the formation tube. It is used when the machine has been
stopped with a "Stop in Phase" and the film is locked, but manual
operations (such as trying out a new film) must still be performed.
To relock the film, press “Reset”.

This button can be used when the machine is at standstill. It can be

useful when carrying out particular adjustments requiring reverse
movement of the CL100 catenary

This button can be used when the machine is at standstill. It can be

useful when carrying out particular adjustments requiring slow
forward movement of the CL100 catenary

Press this button, when the machine is at standstill, to carry out a

manual step of the machine from pod forming to packing in bags.

It is a button that allows to make a reverse rotation of the dosing

auger. It is used in case of product sticking at the purpose to
unblock it.

Press this button for access to the alarms storage page.

È un pulsante che premuto permette di accedere alla pagina delle

segnalazioni di allarme.

Press this button to dialogue with the machine in Italian

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Press this button to dialogue with the machine in English.

Press this button for access to the programming page

Press this button for access to the switches page

This button is used to clearing any alarm warning data signalled in

a line of text.

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5.2.2 Programming page

Get access to this page by pressing the key on the MAIN page.

This page contains buttons that are used to access other pages, as follows:
Key Function

Press this button for access to the programs or recipes page.

Press this button for access to the welders temperature page.

Press this button for access to the speed page.

Press this button for access to the times CL100/S page.

Press this button for access to the times Monopack page.

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Press this button for access to the counters page.

Press this button for access to the cams CL100/S page.

Press this button for access to the cams Monopack page.

Press this button for access to the commands page.

This button accesses the system settings page.

This button access the alarms page.

IMPORTANT:

The following programming pages display a series of buttons which have the same
function in every page. The symbols together with the functions are given below.

Key Function

Press this button for access to the programming page.

Press this button to return to the main page.

Press this button to dialogue with the machine in Italian

Press this button to dialogue with the machine in English

Use this button to reset any alarm warning given in the line of text.

This button can be used when the machine is at standstill. It can be

useful when carrying out particular adjustments requiring reverse
movement of the CL100 catenary
This button can be used when the machine is at standstill. It can be
useful when carrying out particular adjustments requiring slow
forward movement of the CL100 catenary

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The data appearing on the following pages may be modified by

the operator.
To vary the desired parameter, touch the relative field. A
keyboard will then appear that can be used to enter the new
number and confirm it with the Enter key.

A password must be entered before the new value can

be entered.

IMPORTANT:

The subpages mentioned above will now be described individually. The procedure
for changing machine programming is described on all these pages. Even though
this procedure is presented, we recommend that you do not change the
programming (unless you receive written approval from OPEM technicians)
because such changes may cause the system to malfunction.

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5.2.2.1 Recipes page

This page is accessed from the main page by pressing .

The purpose of the recipes (or programs) is to transfer bundles of data from the control
panel to the controller, and vice-versa.
The programs (or recipes) stored in the machine depend on the type of production that the
user intends to perform.

The following items appear on the screen (from top to bottom):

- the number and a description of the current recipe
- the procedure for saving data in a recipe
- the procedure for copying a recipe
- the procedure for changing a recipe
- a series of buttons, which are described below
All the procedures that can be performed on this page are described in detail on the
display and are also reported below.

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Saving data in a recipe

If any values in a recipe have been changed and you wish to save the changes, make
sure the number and name of the current recipe are the ones for the recipe you wish to

save. Now, press .

Copying the current recipe

To copy the current recipe into a new recipe, proceed as follows:

- on the following line, enter the number of the target recipe where you wish to copy the
source recipe

- and press

Copying a recipe into another recipe

To copy a recipe into a new recipe, proceed as follows:

- on the following line, enter the number of the source recipe you wish to copy

- on the following line, enter the number of the target recipe where you wish to copy the
source recipe

- and press

Changing the current recipe

To change the current recipe, proceed as follows:

- on the following line, enter the number of the recipe you wish to use as the current
recipe

- and press .
The recipe you specified is now the current recipe.

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Press on the Recipes page to access the recipe (programs) list.

This page lists the recipes stored in the PLC.

Up to 52 recipes can be displayed.
On this page, you can display and choose the recipe you wish to load as the current
recipe.

This page also contains two buttons, whose function is described on the right.

This button calls up the page for managing memory cards.

This button returns the user to the Recipes Page, where recipes are
saved.

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Changing or assigning a name to a recipe

Touch the blue area to the right of the number corresponding to the recipe you wish to
name.

A keyboard will automatically appear which is used to type in the name (see below).
The keyboard will disappear after you type the name and confirm it by pressing Enter.

NOTE: A name should be assigned to each recipe number.

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5.2.2.2 Memory card

This page is accessed from the PROGRAMMING page by pressing .

The memory card was introduced to enable the user to save recipes on this type of card
and to load recipes from the card.
The procedures that can be performed on this page are described in detail on the display.

Saving PLC data on the Memory Card

- To copy data from the PLC onto the Memory Card, press and the
“STOP IN PHASE” button at the same time.

- To copy data from the Memory Card onto the PLC, press and the
“STOP IN PHASE” button at the same time.

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5.2.2.3 CL100 Times Page

This page is accessed from the PROGRAMMING page by pressing .

This page contains programmable values (in seconds) for the durations of the movements
made by the various mechanical systems on the machine.

To move to the next times page, press .

The operator can program the values on this page.
The individual times are described below.
The values shown on these pages are the values programmed by Opem technicians
during final testing.

IMPORTANT:

Even though instructions are given for varying the times on the following pages, we
recommend that you do not change the values that were programmed during final
testing unless you receive written approval from OPEM technicians.
The original values may be changed only by a few hundredths of a second and only
if absolutely necessary.

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Time Description Function

It shows the mouvement time of the blade, which rotates
and keeps the coffee moving in the dosing unit.
You have to reduce the mouvement time in case of
MIXER INTO DOSING
1
UNIT
coarse ground coffee or particularly flowing coffee.
You have to increase the mouvement time in case of
very fine ground coffee or in case of coffee, which has
difficulties to flow.
It shows the delay of the weighing check to weight the
DELAY CHECKWIGHER empty plate.
2
CALIBRATION
Normally the value doesn’t need any variation.
It shows the time between the coming of the pod on the
weigher and the reading of the weight. This delay is
necessary because the fall of the pod causes an
DELAY WEIGHT oscillation on the weight reading. The delay allows a
3
READING correct weight reading after the settlement.
You have to increase the delay in case of an excessive
pods ejection (after a manual verification that the pod’s
weight is in reality correct)
It shows the delay of the air blow, which cleans the
weighing plate after the pod is picked up.
DELAY BLOW ON
4 Normally, the value doesn’t need any variation. You
CHECKWEIGHER
have to change it only if the blow interferes with the
presence of the pod on the plate.
It shows the blow duration on the weighing plate.
BLOW ON
5 You have to increase the duration if the previous blow
CHECKWEIGHER
didn’t clean correctly the plate.
At disposal of OPEM’s technicians for eventual next
6 -AVAILABLE-
modifications.
It shows the delay of the lower filter paper unwinding
from the moment when the sensor advises that the
paper at catenary’s disposal is ending.
DELAY UNWINDING
7
LOWER PAPER
You have to reduce the delay if there are breaches on
the filter paper at catenary’s entrance.
You have to increase the delay if at catenary’s entrance
there is too much filter paper.
It shows the delay of the upper filter paper unwinding
from the moment when the sensor advises that the
paper at catenary’s disposal is ending.
DELAY UNWINDING
8
UPPER PAPER
You have to reduce the delay if there are breaches on
the filter paper at catenary’s entrance.
You have to increase the delay if at catenary’s entrance
there is too much filter paper.

CL100/S + Monopack 57
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This page is accessed from the "CL100 1-8 TIMES" page by pressing .

This page displays the remaining operating times of the CL100/S.

The operator can modify the values appearing on this page.
The individual times are described below.
The values shown on these pages are the values programmed by Opem technicians
during final testing.

IMPORTANT:

Even though instructions are given for varying the times on the following pages, we
recommend that you do not change the values that were programmed during final
testing unless you receive written approval from OPEM technicians.
The original values may be changed only by a few hundredths of a second and only
if absolutely necessary.

To move to the next times page, press . To return to the previous times

page, press .

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Time Description Function

It shows the delay from the warning of the dosing
unit’s level sensor about a product’s lack, to the real
product’s call.
9 DELAY PRODUCT CALL You have to increase the delay time if the operator
notes that there is an excessive stress of the sensor.
You have to reduce the delay time if the machine
frequently signalizes the alarm “PRODUCT MISSING”
It shows the delay from the moment when the dosing
unit’s level sensor signalizes the product’s level
DELAY STOP PRODUCT reinstatement, to the real signalisation that the
10
CALL product’s feeding is stopped.
You have to reduce the delay time if the dosing unit
becomes obstructed because of a too rapid filling.
DELAY START It shows the delay of the horizontal auger’s start from
11
HORIZONTAL AUGER the moment when the sensor calls the product.
It shows the delay of the horizontal auger’s stop from
DELAY STOP
12
HORIZONTAL AUGER
the moment when the sensor doesn’t call the product
anymore.
DELAY ALARM It shows the delay of the alarm sensor for product’s
13
PRODUCT LACK lack, before it lets appear the alarm on the dashboard.
At disposal of OPEM’s technicians for eventual next
14 -AVAILABLE-
modifications.
It shows the time between the production of two pods
without coffee. When an empty pod arrives in the
STEP CALIBRATION OF weighing station, allows the machine to check and, if it
15
CHECKWEIGHER is necessary, to calibrate the tare of the weigher.
The operator will decide the interval on the base of the
weights’ constancy.
Duration of the acustical signalisation to advise the
16 START HOOTER
imminent start of the machine.

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5.2.2.4 Monopack Times Page

This page is accessed from the PROGRAMMING page by pressing .

This page displays the operating times for the Monopack packager.
The operator can modify the values appearing on this page.
The individual times are described below.
The values shown on these pages are the values programmed by Opem technicians
during final testing.

IMPORTANT:

Even though instructions are given for varying the times on the following pages, we
recommend that you do not change the values that were programmed during final
testing unless you receive written approval from OPEM technicians.
The original values may be changed only by a few hundredths of a second and only
if absolutely necessary.

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Time Description Function

It shows the cut’s duration of the bag, which contains
the pod.
You have to increase the duration when the cut is not
1 BAGS CUTTING correctly made.
You have to reduce the duration when the operator
notes that the cutting blade doesn’t come completely
back between a cut and the next one.
It shows the delay, which is necessary to eject the
bags containing empty pods or pods with a wrong
weight.
2 DELAY BAGS REJECT You have to increase the delay if the blow starts
when the bag to eject didn’t reach the eject zone yet.
You have to reduce the delay if the blow starts when
the bag to eject already passed the eject zone.
It shows the duration of the blow, which ejects the
bag.
You have to increase the duration when the blow is
3 BAGS REJECT
not sufficient to eject the bag from the belt.
You have to reduce the duration when the blow
interferes with the bag next to the one to eject.
It shows the reading interval on the count of the
bags, which are going out from the machine.
You have to increase the interval if the count
4 DELAY NEW COUNTING
uncorrectly counts more pods than the real ones.
You have to reduce the interval if the count
uncorrectly counts less pods than the real ones.
It shows the delay from the reading of the last bag of
the current count, to the real displacement of the
diverter. You have to increase the delay when the first
5 DELAY BAGS SHIFTING bag, which has to fall into the empty carton, falls into
the full one. You have to reduce the delay when the
last bag, which has to fall into the full carton, falls into
the empty one.
At disposal of OPEM’s technicians for eventual next
6 -AVAILABLE-
modifications.
At disposal of OPEM’s technicians for eventual next
7 -AVAILABLE-
modifications.
At disposal of OPEM’s technicians for eventual next
8 -AVAILABLE-
modifications.

To return to the previous times page, press .

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5.2.2.5 CL100 Cams page

IMPORTANT:

We recommend that you do not change the programming unless you receive
approval from Opem technicians.
Such changes may cause the system to malfunction.

This page is accessed from the PROGRAMMING page by pressing .

The machine cycle is determined by a motor encoder which issues signals for controlling
the different interlockings. These signals are processed as a series of electronic cams
which can be totally or partially used.
This page gives the variable values for the different cam positions involved in CL100 pod
machine movement. The values ON and OFF are expressed as degrees: because every
machine’s cycle is equal to 360° (turn angle), the action interval of every cam will be an
internal portion at every machine’s cycle (for example, the dosing unit will start when the
machine’s cycle indicates 160° and it will finish when the machine’s cycle indicates 290°).
The variation types are principally 3:
- If one only changes the value on position OFF, one will anticipate or delay the point
where the cam ends its intervention.
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- If one only changes the value on position ON, one will anticipate or delay the
intervention point and, at the same time, will dephase it.
- If one changes both values ON and OFF for the same number of degrees, one will
change the moment when the cam will start to work, and the action interval remains
the same.

Cam Description Function

It shows the position where the pod machine stops, when
the key “STOP IN PHASE” is pressed.
You could change the parameters if the operator notes that,
when the machine starts, the packaging machine is not
STOP ON PHASE synchronized with the packaging making machine.
1 CL100 ATTENTION
We suggest not changing the pre-set parameters (or
only after a communication of Opem’s technicians). The
reason is that the modification could cause a bad
functioning of the machine.
At disposal of OPEM’s technicians for eventual next
2 -AVAILABLE-
modifications.
It shows the interval when the pre-forming blade goes down
PREFORMING between two formats.
3 LOWER PAPER You have to modify the intervention times if the blade, still
down, could break, or hamper the catenary’s mouvement.
It shows the intervention time of the roll, which let the lower
UNWINDING LOWER filter paper slide.
4 PAPER You have to modify the times, if the filter paper breaks, or if
too much filter paper accumulates under the catenary.
It shows the interval when the dosing unit let the doses of
ground coffee fall in the die.
5 PHASE DISCHARGE
You have to modify the intervention times if the dose is not
made when the dosing unit is completely down on the die.
It shows the time, in which the dosing unit, after the dose,
makes a little rotation to give a first shape to the pod.
DISCHARGE
6 ROTATION You have to modify the times if the rotation takes place
during the dose, or when the dosing unit is already far from
the die.
It shows the time in which the compression plug makes a
rotation to create a correct and compact pod.
7 PLUG ROTATION
You have to modify the times if the pod is cracked or if
some coffee remains on the plug.
It shows the suction time of residual coffee, which is out of
the pod.
SUCTION UNDER
8 PLUG You have to modify the times if the suction takes place
when the external tampon’s guide is already taken off from
the pod, or if it isn’t in contact with the die yet.

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To change a parameter, follow the procedure described previously in this manual.

The values shown on this page are the values programmed by Opem technicians during
final testing.

To move to the next page, press .

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This page is accessed from the “CAM CL100 1/2" page by pressing .

The programmable values appearing on this page may vary.

Cam Description Function

It shows the intervention time of the paper lock, which
keeps the waste before the pod is brought to the
weighing check.
9 STOP PAPER ON MILL
You have to modify the times if the filter paper lock
doesn’t keep the waste or if it is still down when the
chain mouvement starts.
It shows the time for the suction of the suction cup,
which brings the pod from the catenary to the weighing
PODS SUCTION FROM check.
10 MILL
You have to modify the times if the transport is not
fluent and correct.

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It shows the position where the packaging machine

stops, when the key “STOP IN PHASE” is pressed.
You could change the parameters if the operator notes
that, when the machine starts, the packaging machine
MONOPACK START is not synchronized with the pod making machine.
11 PHASE ATTENTION:
We suggest not changing the pre-set parameters
(or only after a communication of Opem’s
technicians). The reason is that the modification
could cause a bad functioning of the machine.
It shows the time for the suction of the suction cup,
which brings the pod from the weighing check to the
PODS SUCTION FROM entrancy tube of the packaging machine.
12 CHECKWEIGHER
You have to modify the times if the transport is not
fluent and correct.
At disposal of OPEM’s technicians for eventual next
13 -AVAILABLE-
modifications
At disposal of OPEM’s technicians for eventual next
14 -AVAILABLE-
modifications
At disposal of OPEM’s technicians for eventual next
15 -AVAILABLE-
modifications
It shows the vibration time of the plug.
VIBRATOR ON PLUGS
16 UNIT You have to modify the times if the pod is cracked or if
some coffee remains on the plug.

To return to the previous cams page, press . To move to the next page,

press .
To change a parameter, follow the procedure described previously in this manual.
The values shown on this page are the values programmed by Opem technicians during
final testing.

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5.2.2.6 Monopack cams page

IMPORTANT:

We recommend that you do not change the programming unless you receive
approval from Opem technicians.
Such changes may cause the system to malfunction.

This page is accessed from the PROGRAMMING page by pressing .

The positions of the cams for the Monopack packager are displayed on this page.
To change a parameter, follow the procedure described previously in this manual.
The values shown on this page are the values programmed by Opem technicians during
final testing.

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Cam Description Function

It shows the position where the packaging machine
stops, when the key “STOP IN PHASE” is pressed.
You could change the parameters if the operator
notes that, when the machine starts, the packaging
machine is not synchronized with the pod making
STOP IN PHASE machine.
1 MONOPACK
ATTENTION:
We suggest not changing the pre-set parameters
(or only after a communication of Opem’s
technicians). The reason is that the modification
could cause a bad functioning of the machine.
It shows the range of action of horizontal jaws’
closing.
HORIZONTAL JAWS
2 COMMAND PHASE You have to change the parameters if the operator
notes that the bags’ sealing is not correct or that there
isn’t synchronisation with the cutting phase.
At disposal of OPEM’s technicians for eventual next
3 PHASE WITH CL100
modifications.
It shows the bag’s cutting phase after the sealing.
4 BAGS CUTTING PHASE You have to change the parameters when the cut
isn’t made correctly.
It shows the closing phase of the vertical jaws.
You have to change the parameters if the sealing is
VERTICAL SOLDERING
5 PHASE
not correct.
The working cycle of the vertical jaw has to take place
only when the foil is still.
MOVEMENT SUCTION At disposal of OPEM’s technicians for eventual next
6 UNDER TUBE modifications.
It shows the intervention interval of the pneumatic
cylinder, which locks the bag under the horizontal
BAGS SUCTION UNDER jaws.
7 TUBE The working cycle of the bag’s taking has to take
place when the horizontal jaws are near to the lower
dead point.
SUCTION FOR BAG At disposal of OPEM’s technicians for eventual next
8 TRANSFERT modifications.

To return to the previous cams page, press . To move to the next cams

page, press .

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To move to the next cams page, press .

The positions of the cams for the Monopack packager are displayed on this page.
To change a parameter, follow the procedure described previously in this manual.
The values shown on this page are the values programmed by Opem technicians during
final testing.

Cam Description Functiion

It shows the interval when the photocell, after the
reading of a foil’s spot, is inhibited, in order to avoid
INHIBITION MARK the entrance of anomalous signals till the reading of
9 READING the next spot.
You have to change the parameters if the inhibition
range creates problems to the spot’s reading.
It shows the interval when the photocell has to read
the foil’s spot.
10 MARK CONTROL PHASE
You have to change the parameters if there are
problems on the spot’s reading.
It shows the phase, which controls the correct closing
JAWS CLOSED CONTROL
11 PHASE
of the horizontal jaws, in order to check if there is
dirtiness between them.
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You have to change the parameters if the control

doesn’t take place exactly when the horizontal jaws
are completely closed.
It shows the intervention time of the pneumatic
cylinder, which locks eventual foil’s movements on
the forming tubes.
12 LOCK FILM ON TUBE You have to change the parameters only if the
cylinder hampers the foil drive.
The working cycle of the foil lock has to take place
only when the foil is still.
At disposal of OPEM’s technicians for eventual next
13 -AVAILABLE-
modifications.
At disposal of OPEM’s technicians for eventual next
14 -AVAILABLE-
modifications.
BAG INTAKE UNDER At disposal of OPEM’s technicians for eventual next
15 TUBE modifications.
It shows the opening and closing interval if the film is
OPEN JAWS WITHOUT without spot (usually used for the tests).
16 MARK You have to change the parameters on the base of
the bag’s length, which you want to produce.

To return to the previous cams page, press .

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5.2.2.7 Speeds Page

IMPORTANT:

We recommend that you do not change the programming unless you receive
approval from Opem technicians.
Such changes may cause the system to malfunction.

This page is accessed from the PROGRAMMING page by pressing .

The programmable speeds of the motors on the machine are displayed on this page.
To change a parameter, follow the procedure described previously in this manual.
The values shown on this page are the values programmed by Opem technicians during
final testing.

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5.2.2.8 Counters Page

This page is accessed from the PROGRAMMING page by pressing .

The system that counts the bags is located on the outlet of the vertical conveyor. A divider
shunts a programmed number of pods to the right or left. In this way, two containers can
be placed at the outlet of the conveyor, and the machine can continue to fill one container
while the other container is replaced after being filled up.
This page displays the programmed number of pieces at which the machine will shut
down.
The PRESET value is the programmed number of pieces.
The MANCANTI value is the number of pieces remaining before the PRESET quantity is
reached. This value cannot be programmed because it is simply an indicator of a quantity
that varies with the number of pieces produced.
To vary a PRESET quantity, press on the respective value to the right of the wording on the
screen.
This page also contains the following selector, whose function is described on the right:

This selector is used to enable and disable the counters. If the

counters are disabled, the machine will operate continuously until it
is stopped.

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5.2.2.9 Temperatures

This page is accessed from the PROGRAMMING page by pressing .

This page contains programmable values for the temperatures on the vertical and
horizontal jaws and on the pod sealer, expressed in °C.
The items on this page that are labeled "set point" and "correction" can be modified.
To change a parameter, touch the desired value and follow the procedure described
previously in this manual. The values shown on this page are the values programmed by
Opem technicians during final testing. This page also contains several buttons, whose
function is as follows:

Button Function
This button automatically calculates the parameters (PIDs) that regulate
the sealing jaws on the Monopack packager. It is generally used only
when the machine is first placed into service or after the jaws are
replaced.
This button automatically calculates the parameters (PIDs) that regulate
the sealing jaw on the CL100/S. It is generally used only when the
machine is first placed into service or after the jaw is replaced.

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This button provides access to the page displaying the PIDs

(programmed values) for the temperatures.

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This page is accessed from the TEMPERATURES page by pressing .

This page contains programmable correction values (P.I.D.) for the temperatures on the
horizontal and right-hand vertical jaws.
The operator can modify the values appearing on this page.
To change a parameter, touch the desired value and follow the procedure described
previously in this manual.
The values shown on this page are the values programmed by Opem technicians during
final testing.

To return to the previous page, press .

To move to the next parameters page, press .

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This page is accessed from the TEMPERATURE PARAMETERS 1 page by pressing

This page contains programmable correction values (P.I.D.) for the temperatures on the
left-hand vertical jaws and the jaw that seals the pods.
The operator can modify the values appearing on this page.
To change a parameter, touch the desired value and follow the procedure described
previously in this manual.
The values shown on this page are the values programmed by Opem technicians during
final testing.

To return to the previous pages, press or .

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5.2.3 Machine Controls

This page is accessed from the MAIN page by pressing .

This page contains a series of selectors (keys with a red background) and two buttons.
When the function controlled by a selector is enabled, the background color changes from
red to green.

Button Function
This button is used to advance the carousel on the CL100/S slowly when
making special adjustments.

This button is used to reverse the carousel on the CL100/S slowly when
making special adjustments.

The selectors on this page enable or disable certain functions in the system. The selectors
must be switched before the system is started to obtain the desired type of production.
The function of each selector is described below.

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Selector Function
This selector is used to enable and disable the machine that
prepares the pods (CL100/S).

This selector is used to enable and disable the MONOPACK bag

packager.

This selector is used to enable and disable the filler unit during the
production cycle.
This selector is used to enable and disable the system that
empties the filler unit. The grinder will not unload product when this
system is disabled.
This selector is used to enable and disable the suction cups that
withdraw the pods from the carousel.
This selector is used to enable and disable the clogged tube alarm.
This alarm can be disabled so that the machine will not shut down
if the formation tube clogs while tests or adjustments are
performed on the CL100/S.
This selector is used to enable and disable temperature control on
the sealers.

This selector is used to enable and disable the weight control

system.
This selector is used to enable and disable the photocells that
check for filter paper. It is used to prevent the paper from being
torn when performing maintenance or tests.
This selector is used to enable and disable the photocell that
checks for the mark on the film.
This selector is used only when performing tests.
When only the CL100/S is used, the system that cuts the filter
paper can be disabled with this selector so that pods are drawn in
together with the scrap, which prevents the pods from falling under
the carousel.
This selector is used to enable and disable the suction units when
the machine is stopped. This selector must be enabled during the
production cycle.
This selector is used to enable and disable the system that injects
inert gas into the bags during the production cycle.

This selector is used to enable and disable the motor braking

systems on both machines during maintenance.
This selector is used to enable and disable the counter during the
production cycle. If the counter is disabled, production will continue
but the pieces will not be counted.
This selector is used to enable and disable the (accessory) suction
cup system that places the pods on the conveyor underneath the
formation tube.

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This selector is used to enable and disable the horizontal auger on

the filling unit. If the auger is disabled, product will not be
dispensed by the filling unit.
This selector is used to enable and disable the (accessory) film
marker during the production cycle.
This selector is used to enable and disable the photocell that reads
the mark on the film. If the photocell is disabled, production will
continue even though the distance between marks is incorrect.
This selector may be useful when performing certain tests that
require continuous, uninterrupted operation.
This selector is used to enable and disable logo printing during the
production cycle.
This switch disables synchronization with the next machine on the
production line. When synchronization is disabled, the machine will
ignore signals from the next machine on the line and operate
continuously.

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5.2.4 Alarms page

The first alarms page is accessed from the MAIN page by pressing .

This page contains a chronological list of the alarms that have occurred on the machine.
The page is only used for monitoring alarms. On this page, the status of machine
operation can be checked, and any alarms that occur more frequently can be identified.

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5.3 - DOSING UNIT COMMAND PANEL

The following procedure is useful for connecting the machine online and starting it up;
obviously these instructions are only given as a general outline and technicians
responsible may make any adjustments they consider necessary according to the
circumstances and the specific case history of each individual installation.

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5.3.1 Machine dialogue

Your machine has a graphic display for viewing diagrams and data which can be set using
the special diaphragm keyboard.

FRONT VIEW OF ELECTRONIC EQUIPMENT

It should be stated beforehand that the machine program is scheduled with a two access
level password with the option of preventing unauthorised access to certain configuration
parameters of the machine. Please turn to paragraph 8.0 for a more detailed description
of these. When the machine is switched on it automatically prepares the WORK PAGE:

PROD:01
++ | | | | | | | |
WEIGHT:+000.00g

The following data is displayed and refers to the product being produced at the last
shutdown:
- DATE and TIME
- "WEIGHT" or "ERROR" read on the last checked piece (commutable by pressing the
ENTER key).
- "PARAMETERS" set for the product or "RESULTS" statistics.
- Average error and current production.
Use the MENU key to activate/deactivate the MAIN MENU.
Use the and keys to browse through the different entries of the MENU included in the
program.
Use the ENTER key to enter the submenus and to set program values.
Use the numeric keys to enter numeric values or alphanumeric strings in the special fields.
Use the  and keys to shift between the characters of a string or to select various
options for example printing or to cancel results. When a character is highlighted negative
against a dark flashing background it means that this character, or the function
represented by the initial letter, is active and can be modified using the  and , ENTER
or CLEAR keys, according to the function. Note that the cursor can be moved, to activate
a function or a character, using the  and keys and moving from left to right and from
top to bottom.
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EXAMPLE: the activated PRINT command is rendered executable by seeking the PRINT
function and pressing ENTER for at least 2 seconds, CANCEL data by shifting onto the
CLEAR function, pressing the key once and ENTER for at least two seconds,
confirmation is given by a completed bar on the display. It should be noted beforehand
that the machine program includes space for entering "key software" (6 alphanumeric
characters set at the user’s discretion) to prevent unauthorised personnel getting access
to particularly important parts of the program; refer to the following paragraphs for use.
Protected data or parameters are highlighted by bleached “FONT” which automatically
disappears the moment the correct "access code", which excludes this protection, is
logged in. Data relating to the last shutdown can also be viewed on this page. The data
displayed (moving from left to right and from top to bottom) is:

- NUMERIC PRODUCT REFERENCE CODE (from 01 to 100).

- PRODUCT CODE (8 characters set at will)
- WEIGHT given for last piece checked
- CURRENT WORK POSITION of the machine
(T: tare; -: reading lag; L: reading).

Press the and keys at the base of the display for access to the following sequence of
"windows":

- DATE and TIME

- VIEWING OPTION, as well as CANCELLATION or immediate PRINTING (if the
machine is connected to a printer) of production data.
- FEED BACK N.
- RESULTS PRINTING RESET
- AVERAGE WEIGHT
- STANDARD DEVIATION
- TOTAL WEIGHT
- TOTAL PIECES CLASSES "--" and "-"
- TOTAL PIECES CLASSES "OK" and "+"
- TOTAL PIECES CLASSES "++"
- GENERAL TOTAL and TOTAL PIECES ACCEPTED

Use the MENU key to shift alternatively from the WORK PAGE to the MAIN MENU page;
from the latter use the and keys to get access to the subpages listed below.

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5.3.2 Program structure

MAIN ITALIAN MENU

MAIN MENU PRODUCT

SELECTION

MAIN MENU
ALARMS

MAIN MENU
GENERAL PARAMETERS

MAIN MENU
PRODUCTS REGISTER

MAIN MENU
CALIBRATION

MAIN MENU
MONITOR

MAIN MENU
ADJUSTMENT

MAIN MENU
CONFIGURATION

MAIN MENU
CONFIGURATION

MAIN MENU
INPUT OUTPUT

MAIN MENU
REMOTE TERMINAL

MAIN MENU
PASSWORD

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5.3.3 Product selection

Use this function to select with “MACHINE RUNNING” the product used from a list of a
100 in storage.

5.3.4 Alarms

The machine has its own self-diagnosis system which gives the code and an abbreviated
description of the causes leading to an alarm situation, shown by a flashing exclamation
point on the work page. Press the “ALARMS” key on the MAIN MENU for access to this
subpage and the following list of alarm causes: N° of times the alarm has been repeated
and the type of alarm. Press the CLEAR key to eliminate alarm/alarms conditions, press
MENU to return to the work page.

There are two possible groups of alarm causes

00 DRIVE COMMUNICATION
(This alarm appears when communication is interrupted between the
scales and the relative drive, check connections between the 485
interfaces)

01 OUTSIDE MINIMUM SCALE

(This alarm appears when the loading cell is loaded over its lower limit or is
permanently deformed and needs replacing).

02 OUTSIDE MAXIMUM SCALE

(This alarm appears when the loading cell is loaded over its full-scale limit or is
permanently deformed and needs replacing).

Please contact our technicians if signals should remain active, after removal of the cause
for alarm and restoration.

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5.3.5 Calibration

A – LOADING CELL CALIBRATION

Cell "CALIBRATION" is carried out by OPEM technicians during general machine testing
and inspection and therefore alterations should not be made without first consulting the
Opem after-sales service. Users should, however be familiar with the procedure in case of
need and to cover all eventualities. Use the and keys on the MAIN MENU page to
view the “MAIN MENU Calibration” window, press the ENTER key to display the relative
subpage and the relative calibration weight of the product to be tared, press the key
again to view a page containing the digital value of the “Z+/-X” zero, the “G X” gain and the
percentage load of the cell (X%). Using an empty scale pan act on the "ZERO" (“Z+/-X”)
by pressing the ENTER key and use the “INC” and “DEC” keys to correct the value and
bring the percentage load of the cell to around 3%. Thus position the “ ” key on the
"GAIN" (GX) digital value, load the scale pan with the SAMPLE WEIGHT (usually equal to
or slightly above the heaviest product to be checked) and use the “INC” and “DEC” keys to
correct this value and bring it to around 80% of the percentage load of the cell; if it is
impossible to obtain the number, position the cursor on a value circa 10% less than the
maximum which can be obtained. Remove the SAMPLE WEIGHT and check that the
"ZERO" is still on the initial value, if it is not adjust the value again using the “INC” and
“DEC” keys. The two operations must be repeated until the position of the percentage load
is stabilised; this is necessary as the two values influence each other. This operation
couples the electronic unit to the loading cell and leads to optimal exploitation. Thus
proceed with machine calibration in function of each product to be dealt with on the line as
follows.

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B - CALIBRATION USING THE PRODUCT SAMPLE

To carry out a calibration phase:

Use the and keys on the MAIN MENU to view the “MAIN MENU Calibration” window,
press the ENTER key to view the “Calibration weight” subpage press ENTER and enter
the exact weight of the sample, which is usually equal to or slightly higher than the
heaviest product to be checked, then proceed as follows:

1. Press the key once and seek the last window to view the current static weight and
percentage load of the cell.
2. With an empty scale pan, press the “CLEAR” key for at least two seconds to zero set
the weight value or reading
3. Place the product sample corresponding to the “Set calibration weight” and press the
“ENTER” key for at least two seconds.

At this stage the weigher is calibrated and ready for use.

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5.3.6 Products register

Use this function to view a list of the parameters available for each individual product.
Browse through the list on the screen by pressing the " " and " " keys. Select the
parameter to be altered and press “ENTER”; if the value can be set on the keyboard, a
null string will be displayed for entering the new value. Confirm by pressing “ENTER”
again. However if the parameter can only be varied between pre-established fields, press
the "INC" and "DEC" keys to select the values we require and confirm by pressing
“ENTER” again. The following data can be set for each of the 100 stored products:

PRODUCT CODE An alphanumerical value used for the product code.

AMOUNT Can be set from 0 to 9999, gives the number of pulses which
correspond to the product dosing.

SPEED Can be set from 0 to 99%, gives the percentage value of the
dosing speed to transmit to the inverter.

ACCELERATION Can be set from 0 to 1.99 s, gives the dosing acceleration

parameter to transmit to the inverter.

S CURVE Absolute value of the type of acceleration curve to transmit to

the inverter

WEIGHT OK Can be set from 0 to 99.99 grams gives the gross weight of the
product dealt with.

NET WEIGHT Can be set from 0 to 99.99 grams gives the net weight of the
product used.

LIMITE " -- " Can be set from 0 to 99.99 grams, gives the maximum deviation
allowed by WEIGHT OK; all the objects which weigh less than
this limit are placed in the "--" class (generally considered
unacceptable and consequently expelled from the line) while
those which weigh above it are classified "-" (includes between
the "--" limit and the "-" limit) in other words underweight but
generally acceptable.

LIMITE " - " The same as above, it identifies the boundary between the "-"
and "OK" classes. All the objects which weigh between the “-“
and the “OK” limit are considered correct weight and classified
“OK”.

LIMIT " + " As above but identifies the boundaries between the "OK" and
"+" classes; all objects which weigh between the "-" and the "+"
limits are thus classified "OK".

LIMIT " ++" As above but identifies the boundaries between the "+" and
"++" classes. NOTE: a totalisator is displayed for each of the 5
classes listed in the “PART.TOTAL MENU”.

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FILTER The digital filter attenuates oscillations in proportion to the set

value (normally set in pre testing phase by Opem technicians,
avoid altering this value without prior examination or agreement
with OPEM after-sales service).

AVERAGE FEED BACK Indicates the number of objects to be considered when

calculating the average weight for any dosage correction
upstream.

FEED BACK This requires setting the maximum number of objects in "transit"
EXCLUSIONS between the dosing unit part of the machine and the weight
check in order to exclude them from machine calculations. As
these objects were filled before the last correction, they might
lead to another unnecessary, undesired touch-up.

FEED BACK Establishes the discreet value in impulses which can be used
CORRECTION STEP from F.BACK STEP correction.

FEED BACK Value to be set in function of the ratio between the number of
COEFFICIENT correction impulses of the relative amount and following
variation in the quantity of product dosed.

FEED BACK The absolute value of the Feed Back work band outside which
CORRECTION FIELD F.BACK will not operate

HISTOGRAM BAR This function gives the minimum increase of the histogram
base, in grams, the central histogram bar (00) has a double
base value, leading to a half height. The value is set in function
of the object’s weight:
EXAMPLE: Histogram bar 0.5 g graphical scale from - 4 to +
4 grams.

LENGTH OF TARE Establishes the effective TARE length on the weighing scales

READING LAG This data, expressed in ms., delays or brings forward the
weight reading of each individual object, thus excluding
readings carried out in the scale pan preparation phase.

READING TIME Expresses, in ms, the effective duration of the weighing phase.

IMPORTANT - The last three CORRECTION data and the FILTER parameter are the
results of accurate calibration, carried out by OPEM personnel, in the testing phase;
they should not be altered without first contacting the OPEM after-sales service.

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5.3.7 General parameters

This function gives access to a page containing all the machine’s general data,
independent of the dimensions, weight or feeding rate of individual products. The machine
uses this data to set the parameters for its work cycle. The information is given in list form
and can be browsed through by pressing the " " and " " keys. Once the parameter has
been chosen press “ENTER”; if it is a value which can be set on the keyboard, a null
string will be displayed for entering a new value. Confirm by pressing “ENTER” again. If
instead the parameter can only be varied between some pre-established fields press the
"INC" and "DEC" keys to select the required value. Confirm by pressing “ENTER” again.

LINE CODE Set from 0 to 9999, at the user’s discretion, it identifies the data
source when there are several machines on the line.

F. BACK This function connects F.BACK

CONNECTION

FEED BACK TYPE Use this setting to select PROPORTIONAL or STEP type feedback.
PROPORTIONAL F.BACK calculates, in function of the dosing
correction constant (“F.BACK COEFFICIENT”) the relative amount to
be transmitted to the corresponding inverter of the dosing unit
STEP F.BACK applies a correction to the dosing amount equal to
the set “correction step” for each individual weighing station.

CALIBRATION This is the weight used for calibrating the machine

WEIGHT

RESOLUTION Use this option to choose the resolution for the displayed weight
(0.01; 0.1; 0.5; 1; 2; 5; 10; 20 g ).This parameter is set in the pre-
testing phase by OPEM technicians. The value set is chosen on the
basis of the weight class of machine operations. Alter using the INC
and DEC keys.

CUSTOMER NAME Used for alphanumerical setting of customer’s name

USER PASSWORD Use this option to set the user access code.

SUPERVISOR Use this option to set the supervisor’s access code.

PASSWORD

CELL OFFSET Numerical setting of the digital value of zero using the “INC” and
“DEC” keys

CELL GAIN Numerical setting of the digital value of the gain using the “INC” and
“DEC” keys

BEEP AT EVERY Functions on pre-established fields. Press the “+” e “-“ keys to
KEY connect or disconnect the sound when keys are pressed.

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5.3.8 Print Configuration

This is for setting the required type parameters and printing method.

PRINTING TYPE Use the “+” and “-“ keys to select between two printing types (40 or
80 columns).

AUTOMATIC Use the “+” and “-“ keys to select whether or Not to carry out
PRINTING automatic printing of production data

PRINT RATE Function activated if automatic printing is chosen, gives the printing
rate in minutes

After adjustment remember to press the “MENU" key to return to the work page.

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5.3.9 Configuration communication

The weighing machine is designed to "dialogue", according to a protocol of serial

communication, with the centralised line management/control unit or with a simple data
collection device; some parameters of data transmission can be selected to give the
machine maximum versatility. Press the "CONF. COMUNIC." function key and then the
relative key to get access to the following parameters:

MACHINE CODE Numerical code used to identify the machine in the event that
there is more than one.

BAUD RATE Speed of data dispatch from the machine to the receiving unit;
select using the “+” and ”-“ keys. Choose values between 110 bps
and 115200 bps.

BITS DATA Number of bits used to code the characters transmitted (selection
possible between value 7 or 8).

PARITY Bit parity check of characters transmitted (selection possible

between NONE, ODD or EVEN).

BITS STOP Number of bits pause added between one character and the next
(selection between value 1 or 2 using "+" or "-" keys).

When the adjustment is completed remember to press the “MENU" key; to return to the
work page

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5.3.10 Clock Adjustment

Pass from the third page of the menu to the CLOCK ADJUSTMENT page to correct the
following data:
the day of the month
month
year
hour
minute

” and “ ” keys, and correct it using

Move the cursor onto the data concerned using the “
the "INC" and "DEC" keys. When the adjustment is completed remember to press the
“ENTER" key; to return to the work page.

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5.3.11 Monitor

The oscilloscope function can be summoned from the main menu, to get access from the
WORK PAGE press the "MENU" key once, seek the monitor function and then press the
“ENTER" key. This function shows the advancement of the weighing "curve" and
steamlines setting up the reading phase using a vision similar to a digital oscilloscope. At
this point, you must remember that the weight value revealed by the machine represents
the result of an average, calculated at the right moment, between numerous individual
values of suitable weight revealed with the frequency of 1 kHz. The monitor function
records loading cell stress on a diagram which illustrates the weighing cycle in function of
the signal variations of the loading cell. The line representing cell loading can be divided
into three bars to identify the different phases of the weighing cycle of the machine.
These include:
- A first bar which identifies the machine phase coming from the weigher
- A second bar which indicates the start of the weighing cycle (End reading lag).
- A third bar which indicates the end of the weighing cycle (End reading time).

The space between bar 1 and bar 2 represents the effective weighing time

- Use the " " and " " keys to vary the vertical POINTS/DIVISION of the page for
detailed analysis of the weighing curve.
- Press key “2” to activate the “CENTER” command which automatically places the
curve in the centre of the screen
- Press key “3” to activate the “DOT JOIN” command and view the curve in two ways:
1. A collection of points representing the effective values filtered digitally.
2. The interpolation of these values to aid reading.

As far as vertical zoom is concerned:

1. The “⇐ ⇐” and “⇒
⇒” keys alter the times scale, expressed in ms/div.
2. THE command for setting the operating mode of the oscilloscope.
This can be set at NORMAL, SINGLE or FREERUN by pressing key “1” several times
Use the “CLEAR” key to activate the “HOLD” function which locks/releases the screen on
the last passage. Press the “ENTER” key to get access to the submenu to permit
optimisation of the weighing cycle; and finally the MENU key.
We will now illustrate the operations of the oscilloscope in the NORMAL mode.
A weighing curve is displayed for each weighing phase of the object on the scale pan; if
this does not happen the object must be positioned correctly in the centre of the screen.
Use the arrows on the numeric keyboard to move and reposition in the required position
on the screen. If the display scale is too high, or too low, use the “ ” and “ ” keys (to
adjust amplitude), and “⇐ ⇐” and “⇒⇒” (to adjust the times base). Bar “1” on the curve
illustrates the start of the weighing cycle and bar “2” represents the end. The part of the
curve between “1” and “2” represents the effective reading phase of the weight and must
be positioned on the straight flat part of the curve summit (on the tract where the object is
completely at rest and stable on the scale pan). Note, in particular that the flat tract of the
graph at the base of the curve corresponds to an empty weighing pan and the curve
corresponds to real progressive loading, stabilisation and progressive unloading of the
pan. It is thus obvious that the culminating tract of the curve represents the period of time
during which the object is fully resting on the weighing pan and it is here that actual
weighing must take place. The position and length of "reading" results from manual
adjustment of the parameters described below. Press the “ENTER” key to display the
following submenu and parameters:
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1. TARE LENGTH.
2. READING LAG
3. READING TIME
4. FILTER

Move the " " and " " keys to select the value to be modified and use the "+" and "-" keys
to carry out optimal adjustment. As already mentioned above, if the red line remains
outside the flat tract of the curve it must be corrected using LAG and READING TIME, to
increase these values select using the " " and " " keys and press ENTER again; it is
then possible to write the new value and thus press ENTER again. As we can see at every
alteration of these values the entire reading cycle is moved to centre the reading zone on
the central flat tract of the curve. The line connecting bars “1” and “2” must never be in the
ascending tract of the curve, but at the start of the straight tract and approximately at the
center; after and for following approximations the FILTER value must be modified using
the above method. At each filter correction carry out a new weighing passage and readjust
the corrections to the times previously described (READING LAG and READING TIME). In
the event of the weight curve resulting too filtered, it will become a peak where it is
impossible to position the reading zone in the ideal position, (reading time below 20 ms.);
so the filter value must be decreased. The ideal value for most weighers is a filter between
280 and 440. Instead the TARE TIME value is used for setting the effective tare time, it
must be carried out on a completely empty scale pan. To exit from the correction function
press MENU. In the event of difficulties please contact OPEM s.r.l. after-sales service.
The values corrected on the monitor page are automatically updated on the "PRODUCTS
REGISTER" page.

The different modes for using the oscilloscope described above are:

NORMAL The curve is displayed at every machine step.

To lock the display of a certain passage press “HOLD”.

SINGLE The curve is automatically locked at each machine step. To release and
display the following passages press “HOLD”.

FREERUN Continues to display cell advancement independently of the machine signal;

The curve can be locked in any moment by pressing “HOLD”.

Example of a typical adjustment using the “MONITOR” function.

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5.3.12 Input – Output

Get access to the INPUT OUTPUT function by using the " " and " " of the main menu.
This page monitors the state of input and output of the electronic unit. On the left there are
24 inputs with a relative description. Instead on the right there are 16 outputs with relative
description. Alongside each input there is a luminous symbol (similar to a LED) which
lights up when the input output terminal is in action, on the contrary it remains off when
inactive. This function is useful in the event of verifying a signal for example: forcing the
machine running signal will cause the corresponding led to light up.
The I/O are respectively:

INPUT

17. Reading
18. Reject
19. free
20. free
21. free
22. Run
23. Emptying
24. Ready to run
25. free
26. free
27. free
28. Self-set
29. free
30. free
31. free
32. Reset alarms

OUTPUT

1. Reject anomalous
2. Reject
3. free
4. free
5. free
6. free
7. Alarm transmission
8. free
9. free
10. free
11. free
12. free
13. free
14. free
15. free
16. free

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5.3.13 Remote terminal

This function is dedicated to OPEM technicians for the initialisation phase of the machine.

5.3.14 Password

Use this function to select the access level required to operate the machine. The system
has two access levels: USER level and SUPERVISOR level. When the system is started
up it is not connected to any access level so most of the menu keys are disconnected. To
connect an access level select the sub menu PASSWORD on the MAIN MENU page,
which displays a window for logging the password. If the code introduced is the same as
the user password then the user access level is connected; if it is the same as the
supervisor password than the supervisor access level is connected; if it is different from
both of these than the access levels are disconnected. The user password has a
maximum of 6 alphanumerical characters and capital and small letters are considered
different. These codes can be set on the General Parameters page. Setting an empty
code automatically connects the user access level. The supervisor password consists of a
maximum of 6 alphanumerical characters where capital and small letters are considered
different. These codes can be set on the Machine Configuration page. Setting an empty
code automatically connects the supervisor access level.

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5.3.15 Maintenance rules

As the machines produced by OPEM S.r.l. are intended for use in many different work
sectors, each with their own particular problem areas tied to the environment and different
product characteristics, it is obviously impossible to provide any strict maintanance rules.
We would therefore like to simply remind you that cleanliness is the most important factor
behind correct and long lasting machine operations; it is essential that the machine is
cleaned regularly to remove any dust and product which have accumulated in the sliding
housings of the belts and chains, in the scale pan zone, the photoelectric cells and their
reflectors. Particular attention must be given to the rubber "air jets" which protect the scale
pan connection to the loading cells; remove any accumulations of dirt or product which
might affect smoothness and check regularly that they are intact (infiltration of electric
conductive dust or liquids can irremediably damage the loading cell).

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REAR VIEW

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Example of paper strip

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SUMMARY OF DATE 846

SERIAL NUMBER: - DATE: 10/04/09

CUSTOMER: GALA COFFEE MACHINE TYPE: CL100/S S/N: 655/09
PRODUCT SELECT.: COFFE 7 GR PRODUCT: PODS

General parameters

CODE OF LINE: 0000 CUSTOMER NAME: GALA COFFEE

FEED BACK CONSENT: YES PASSWORD CUSTOMER:
FEED BACK TYPE: STEP PASSWORD SUPERV.:
WEIGHT CALIBRATION: 200.0 G ZERO CELL: -05
RESOLUTION: 0.1 G GAIN CELLA: 1
BEEP EVERY TOUCH: YES

Product register

PRODUCT CODE: 7G FILTER: 0160 MS

QUOTE: 3300 CNT FEED BACK AVERAGE: 0010
SPEED: 3700 RPM FEED BACK EXCLUS.: 0010
ACCELERATION: 20 MS CORRECTION STEP: 0025
CURVE S: 20 MS COEFFICIENT : 080 %
WEIGHT OK: 7.2 G CORRECTION FIELD: 0002.0 +/- G
NET WEIGHT: 7.0 G HISTOGRAM BARS: 0000.1 G
LIMIT - -: - 0002.0 G TARE TIME: 030 MS
LIMIT -: - 0000.3 G READING LAG: 420 MS
LIMIT +: + 0000.3 G READING TIME: 030 MS
LIMIT + +: + 0002.0 G

PRINT CONFIGURATION COMMUNICATION CONFIGURATION

PRINTER TYPE: 40 COL MACHINE CODE: 00

AUTOMATIC PRINT: NO BAUD RATE: 9600
BIT OF DATE: 8
PARITY: NO
STOP BIT: 1

CALIBRATION
CLOCK REGULATION: CALIBRATION WEIGHT: 200.0 G
Z -5 G 1 14 %
0 G 14 %
MONITOR

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5.4 - ALARMS AND SIGNALS

The machine has not got alarms to signal dangerous situations.

5.4.1 Warning hooters

The cutout box has a warning hooter which sounds when the machine starts-up.
The machine starts-up when the warning hooter has finished.

5.4.2 Signal light

A signal light on the electrical cabinet changes color to alert the operator to the
following conditions:
- green = machine is operating
- yellow = alarm signal
- red = stop in phase
- blue = end of roll
- white = lack of product

5.5 - WORKING RANGE AND IMPORTANT POSITIONS

After start-up, the machine operates automatically and does not require a
permanent operator.
The operator uses the cutout box control panel to start-up the machine.

5.6 - OPERATING MODES

The machine operates automatically.
Some push-buttons can be used to carry out operations manually but a manual
cycle operation is not possible.

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5.7 - MACHINE START-UP

Before start-up ensure that there are no foreign bodies inside the machine:
e.g. keys, screwdrivers, rags etc..

- Lock all protective casing

- Ensure that all the stations on the catenary are raised
- Disconnect the manual EMERGENCY BUTTONS (red mushroom-head
buttons).
- Switch on the mains electricity on the electric panel
- Open product feed
- Ensure that the filter paper and film reels are full and in their work positions
- Follow the displayed instructions
- Press the run push-button (green) on the command panel.

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5.8 - MACHINE SHUTDOWNS

The machine may shutdown due to a manual or automatic intervention.
Manual shutdown can be related to limited sections of the system, or an emergency
(all movement is shutdown in the latter situation).
Automatic shutdowns are always due to operation anomalies.

5.8.1 Automatic cycle stop

To stop the machine cycle in phase press the TIMING STOP push-button (red)
found on the control panel.

5.8.2 Emergency stop

These are red mushroom-head push-buttons.
The location of the emergency stop push-buttons is described in Chapter 4.
If pressed a push-button will immediately shutdown the automatic cycle and all
motors.

IMPORTANT:

As it is not always possible to directly intervene, at the right moment on an

emergency push-button, the motors (of the area concerned, if the system is
divided up into several areas)can be instantly stopped by opening the
protective casing.

To re-start the machine, disconnect the emergency stop by pulling, and press the
RESET PUSH-BUTTON ON THE CONTROL PANEL.

5.8.3 Machine shutdown at end of work session

It is recommended to always leave the feedbox empty.
The machine can be stopped at any point in the cycle:
- press an emergency stop push-button;
- disconnect the main electric switch;
- lock the on-off air valve.
- lock the inert gas delivery valve.

5.8.4 Automatic stops

The automatic stops of the machine are dealt with in chapter 9.

It specifies the reasons and types of stops and the procedures for restoring
operations.

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5.9 - SETTING-UP AND ADJUSTMENT

After being tested by OPEM technicians, the machine is adjusted and there is no
need for further adjustments during operations.
Chapter 7 gives starting up and adjustment operations for exceptional maintenance
work.

5.10 - MANUAL OPERATIONS

Some manual operations can be carried out using the command panel but not a
complete work cycle.

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5.11 - AUTOMATIC CYCLE

This paragraph gives a description of the automatic work cycle of the machine

The “CL100/S” packaging machine produces pods containing ground coffee made
from reels of filter paper and inserts them in single dose packs, made from a reel of
thermal retractable film. Inert gas is added to the single dose packs. The pod is
formed in small die on a catenary where the auger dosing unit deposits a set
amount on the lower filter paper. Next to the dosing unit there is a pre-forming pad
which is lowered onto the paper to shape it. After being deposited on the filter paper
the coffee dose is passed under pad and pressed. In the following stations the pod
is sealed and cut. The finished pods are collected from the dies by a pneumatic
system and individually weighed by a loading cell: those outside a determined
weight tolerance are discarded. After the forming cycle, the pods are inserted in
single dose packs. The film used for creating the bag is sealed vertically and
horizontally. Before the completed bag can drop it is stopped by a bag- blocking
pad and placed on the delivery belt, which transports it to the belt elevator. Off-cuts
from the above procedure, producing pods for single dose packs, are sucked up by
a special suction pump. The work cycle is managed by PLC with alphanumeric
interface display and self-test function, manual commands and work program
selection Some groups are controlled by electronic starters or frequency changers
to obtain smooth stops and starts and speed variations.

5.12 - SUPPLY CONTROL

The machine must be fed with reels of film in the special loader.

5.13 - ACCESSORIES AND EQUIPMENT

When operating in an automatic cycle the machine does not require accessories
and equipment.

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