Operating Manual - Press

WALTEC
OPERATING MANUAL
Electronic Control DG production
line
WALTEC, Maschinen GmbH, Kronacher Str. 2, D-96352 Wilhelmsthal, 07/2015
Operating Manual - Electronic Control Press line,z-en.doc
WALTEC
Note: The operating instruction manual is valid for several machine types and
configurations. Sections that relate to modules and/or devices, which are
not contained in the extend of the delivery, become irrelevant.
Note: We reserve the right to make changes based on technical advancement.
Danger: It is not allowed to operate the machine/plant without the installed and
intact safety installations and protection devices!
The fundamental and special safety instructions in Operating Manuals of
machines or in the Technical Documentation must be observed strictly!
WALTEC
Maschinen GmbH
Kronacher Str. 2a
D-96352 Wilhelmsthal/Steinberg
Telefon: +49 (0)9260 99 01-0

Fax:+49 (0)9260 99 01-99
Email: info@waltec.de
Online: www.waltec.de
WALTEC
Table of contents
1
FUNDAMENTAL SAFETY INSTRUCTIONS
1.1
Warnings and symbols
1.2
Basic operation and designated use of the machine/plant
1.3
Organisational measures
1.4
Selection and qualification of personnel - Basic responsibilities11
1.5
Safety instructions governing specific operational phases
12
1.5.1
Standard operation
12
1.5.2
Special work in conjunction with utilisation of the machine/plant and
maintenance and repairs during operation; disposal of parts and consumables
13
1.6
1.6.1
1.6.2
1.6.3
1.6.4
1.6.5
1.6.6
Warning of special dangers

Electric energy
Gas, dust, steam and smoke
Hydraulic and pneumatic equipment
Noise
Oil, grease and other chemical substances
High temperature
15
15
16
16
16
17
17
1.7
Mobile machinery and equipment
17
ELECTRONIC LOGIC CONTROLLER
19
STRUCTURE OF CONTROL CABINET
19
DESCRIPTION OF THE FUNCTIONS IN THE CONTROL CABINET20
4.1
4.1.1
4.1.2
4.1.3
4.1.3.1
4.1.3.2
4.1.3.3
4.1.3.4
4.1.3.5
4.1.3.6
4.1.3.7
4.1.3.8
4.1.3.9
4.1.3.10
4.1.3.11
Screen and keyboard

Description of the screen
Function Description
Screen Description
Screen Description: Basic mask
Screen Description: Manual
Screen Description: Indexing Table
Screen Description: Pressing Cylinder A
Screen Description: Pressing Cylinder B
Screen Description: Pressing Cylinder Curve
Screen Description: Pressing Cylinder A/B
Screen Description: Kick-out and blow out nozzle
Screen Description: Mould lubrication, Gob funnel, Cooling
Screen Description: Closer and Opener
Screen Description: Take-out HVM
21
21
21
21
22
24
26
29
32
33
35
36
38
40
42
3
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4.1.3.12
4.1.3.13
4.1.3.14
4.1.3.15
4.1.3.16
4.1.3.17
4.1.3.18
4.1.3.19
4.1.3.20
4.1.3.21
4.1.3.22
4.1.3.23
4.1.3.24
4.1.3.25
4.1.3.26
4.1.3.27
4.1.3.28
4.1.3.29
4.1.3.30
4.1.3.31
4.1.3.32
4.1.3.33
4.1.3.34
4.1.3.35
4.1.3.36
4.1.3.37
4.1.3.38
4.1.3.39
4.1.3.40
4.1.3.41
4.1.3.42
4.1.3.43
4.1.3.44
4.1.3.45
4.1.3.46
4.1.3.47
4.1.3.48
4.1.3.49
4.1.3.50
4.1.3.51
4.1.3.52
4.1.3.53
4.1.3.54
Screen Description: Take-out Cam I HVM

Screen Description: Take-out Cam II HVM
Screen Description: Fire polishing machine (FPM)
Screen Description: Fire polishing Blow Off & Blow out
Screen Description: Burner movement I (and II)
Screen Description: Burner movement II
Screen Description: Cross conveyor & Stacker
Screen Description: Manual polishing machine
Screen Description: Additional functions
Screen Description: MASTER AXIS
Screen Description: Message display
Screen Description: Message archive
Screen Description: CPU diagnosis cache
Screen Description: Data Record Processing
Screen Description: Program information
Screen Description: Mould selection
Screen Description: Glass thickness measuring
Screen Description: Mould Temperature
Screen Description: Mould Temperature Trace
Screen Description: Residual time
Screen Description: Faults Sinamics
Screen Description: Service
Screen Description: Status Profibus
Screen Description: Machine data indexing table press
Screen Description: Machine data pressing cylinder A
Screen Description: Machine data Scaling analogue input
Screen Description: Limitation
Screen Description: Machine Data SINAMICS
Screen Description: Status Sinamics
Screen Description: Status Infeed
Screen Description: Status CU320
Screen Description: Status TM31
Screen Description: Trace S7
Screen Description: Machine Data burner LINDE
Screen Description: Mada Record Processing
Screen Description: Lubrication
Screen Description: Management date and time
Screen Description: Status digital inputs
Screen Description: Status digital outputs
Screen Description: Status analogue inputs
Screen Description: Cooling indexing table
Screen Description: Trace temperature
Screen Description: Status / Control
43
44
45
47
48
49
50
52
53
54
57
59
60
61
63
64
65
67
68
69
71
75
77
78
80
84
85
87
89
91
92
93
94
96
97
98
98
100
101
102
103
104
105
TURNING ON THE MACHINE AND SET-UP MODE
106
INITIAL POSITION AND AUTOMATIC OPERATION
108
6.1
Initial Position
108
6.2
Engagement of Automatic Mode
108
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6.3
Monitor circuit
108
6.4
Settings in automatic mode
109
6.5
Running Machine Empty and Shutting off
109
6.6
Malfunction in Automatic Mode and EMERGENCY OFF
109
6.7
Malfunctions and their Rectification S7-300
111
6.8
Overall Reset of the control S7-300
112
ADJUSTMENTS WHEN CHANGING AN AXLE DRIVE
113
7.1
Necessity for Approaching the Reference Point
113
7.2
Approaching the Machine Reference Point
114
7.3
Calculating the Reference Point Displacement
115
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Foreword to the operating instructions

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

4.1.2 Function Description
The machine is controlled via touch screen as well as via the switches in the
control panel. Via switches 0-I the different machine functions can be switched
on and off.
The control system is structured as a follow-on control system. After switching on
the control, after some seconds the first screen appears. Going out from this
screen, with the touch screen you can request the other screens.
4.1.3
Screen Description
See device manual
Siemens_BA_Simatic_IPC277_en.pdf &
of CD-ROM on Documents for Electrical assemblies
In the following the most important screens of the machine control are
explained.
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Permanent window
4.1.3.1
Screen Description: Basic mask
Message line
B
A
Figure 2: Basic Mask

With help of the screen masks the plant can be controlled and observed. With the
function keys (F01 to F12) and soft keys (S01 to S18) you can choose all masks. Most
machinery components can also accessed directly by touching them in top view. For
example just tap on cross conveyor [A]. Then page cross conveyor will open. Or tap
on pressing cylinder [B] and page pressing cylinder will open.
Key overlay of basic mask:
F01: Manual functions
F02: Indexing table
F03: Pressing cylinder A
F04: Pressing cylinder A/B
F05: Kick-out
F06: Mould lubrication
F07: Closer/Opener
F08: Take-out GPG
F09: Take-out Cam
F10: Fire polishing machine
F11: Additional functions
F12: Keyboard
S04: Exit
S05: Master axis
S06: Message display
S07: Data record processing
S08: Program information
S09: Mould select
S13: Glass thickness measuring

S14: Mould temperature
S15: Residual times
S16: Language select
S17: Faults Sinamics
S18: Service mask
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Reference: This and the following screens can be used to check

various states of the plant and to set various parameters and
options. How data are entered in the fields is explained in Siemens,
Simatic HMI, IPC277 Multi Panel on the attached CD-ROM
Manuals for Electronic Devices.
Data in permanent window:
Function
Program
Cycles
Press mc.
Polish mc.
Counter
Date and time
Oper. messages
Fault messages
Meaning
Display of the currently processed program.
Display of the currently produced piece number per minute.
Display of the currently set operating mode of pressing machine,
e.g.: MANUAL. Further displays are: AUTOMATIC, REFERRING
(only if a positioning axis is available)..
Display of the currently set operating mode of fire polishing
machine, e.g.: MANUAL. Further displays are: AUTOMATIC,
REFERRING (only if a positioning axis is available).
Cycles
The date and clock time are set in the Mask Setting date and time
(S12 of Service).
In the message line of the permanent window is displayed the
operating messages of the control system and the unit as a whole.
When reason of operating messages is cancelled, message
disappears by itself.
Fault messages are also displayed in the message line of the
window immediately after occurring. They are marked by red back
colour. With the ACK key, you can quit the fault messages. If more
than one message is present, then further messages appears after
first one is quit. When messages are present the lamp inside key
F11 is flashing. By pressing this key you reach figure "Messages"
where you can branch to the operating messages or the fault
messages , they can be leafed through with the keys and .
If an error occurs, the screen shows an icon at S10 in each mask,
when pressed you will be forwarded to the mask Faults
SINAMICS.
23
WALTEC
4.1.3.2
Screen Description: Manual
F01 from Basic mask
Figure 3: Manual mode settings for pressing cylinder and take out
Function
Actual value
Meaning
actual position, pressure, speed and motor and oil temperature of
pressing cylinder A and B and take out are displayed.
Pressure
Velocity
Pressure setpoint for up / down movement of pressing cylinder.

Speed setpoint for up / down movement of pressing cylinder or
take-out turning and arm up / down movement.
Take-out pick up position or place position can be finely adjusted by
adding an offset position. Take out rotating axis is always turning
180.
Offset
Position 1
Position 2
Take-out arms 1 and 2 upper and lower position can be limited by

setting these positions (servo axis software limit).
Take-out arms 1 and 2 upper and lower position can be limited by
setting these positions (servo axis software limit).
Actual values or output fields are mostly displayed in blue colour. Some
actual timing or position values are displayed in red colour. Setpoint values or
input fields are always in yellow colour with red background colour!
24
WALTEC
Position, speed and pressure settings made on the manual pages are only
valid in manual mode of pressing machine (or fire polishing machine
respectively)!
25
WALTEC
4.1.3.3
Screen Description: Indexing Table
F02 from Basic mask
Figure 4: Indexing Table 1

This mask describes the entered positions of the individual stations (e.g.:
pressing) or modules (e.g.: gob chute). It shows the number of the moulds at the
individual positions and which position is currently active.
STEP: Displays the step of the program sequence. This is important to search for
errors in the program.
Reference: In the case of possible program failures please forward the
pertaining number to the WALTEC Company.
Data in permanent window:

DRIVE DIRECTION: With this function the rotation direction of the indexing table can be
changed from clockwise to counter clockwise. In automatic mode the rotation will
be set to working direction.
ON/OFF switches: This buttons enable/disable functions of the periphery individually in
certain situations.
Temp max.:
Max. temperature monitoring by pyroscope
Press stop:
Mould will not be pressed
No gob:
Mould will not be fed
2 gobs in mould:
Mould will be fed with two gobs
Take-out contr.:
Article will not be unloaded from this mould
Temp min.:
Min. temperature monitoring by pyroscope
26
WALTEC
Example:
If the button for the pressing at no gob is set to off, all moulds which has
not been fed will not be pressed.
With F01 (home) you revert to the basic mask.
F02 from Indexing Table
Figure 5: Indexing Table 2
27
WALTEC
Button Register Info from Indexing Table
Figure 6: Info about indexing table registers

For each of the 24 moulds is displayed if mould is enabled and what condition is fulfilled
or not fulfilled to process mould. Green color indicates partial condition is fulfilled. Red
color indicates that partial condition is not fulfilled. If one of the conditions is disabled
related mould is also not enabled (processed).
In example above all moulds labeled B are not enabled because in mould is no gob. In
other words moulds B are not fed with hot glass.
Additionally mould A and B are not pressed and hence are not enabled. Next rounds
these moulds will not be fed with hot glass.
To enable mould all register like no Gob, no Press and so on must be green!
28
WALTEC
4.1.3.4
Screen Description: Pressing Cylinder A
F03 from Basic mask
2
4
C
D
E
F
G
J
K
L
Figure 7: Pressing cylinder A

Function
Step
Actual value
Plunger exchange
Plunger / Ring
lubrication
Residual time
Meaning
Indication of the step in program flow. It is important for fault
finding at the program. Kindly forward the stated number to
WALTEC at possible malfunction of program
Actual temperature of hydraulic oil, servo motor temperature,
hydraulic pressure and speed of pressing cylinder are displayed
When plunger has to be changed it will move to this position with
adjusted velocity.
Delay time and time (duration) for the plunger/ring lubrication can
be set and monitored in this mask. In the figure, the input fields are
shown in dark. The process (actual value) is shown in the fields to
the left.
see Screen Description: Cycle time.
29
WALTEC
Function
Delay time (C2)
Rapid down (D4)

Press-time 1 (F2)
Press-time 2 (G2)
Slow up (J4)
Enable Table (K1)
Rapid up (L4)
Meaning
Delay time cylinder down after start of peripheral equipment by the
signal "Indexing on". Peripheral equipment is all equipment and
devices, which are acting upon exactly one station of the indexing
table
Rapid speed down up to position (E1) Pressing speed down is
valid as long as pressure threshold is reached
with pressing pressure 1 (F3)
with pressing pressure 2 (G3). Pressing time 2 is started, when
pressing time 1 has been terminated
Slow speed up until position (J1)
From this position on the indexing table of machine is enabled for
turning. Already in this position mould parts must not collide to one
another. For security reason Enable table position is set 3mm
lower than topmost position (L1). Keep always in mind that zero
position of pressing cylinder is in top position
Rapid speed upward up to position (L1). When pressing cylinder
reached enable table position (K1) indexing table is allowed to turn
Danger: Enable table position must always be higher than the

mould rim. Please before starting production or after mould change
always check this position. Improper settings may lead to serious
machine damage!
30
WALTEC
In the following graphics the times, pressures and speeds are described in accordance
to the screen together with letters and numbers to indicate the sequence more clearly.
P ositio n
L1
L1
to p
L4
D4
E4
K1
J4
E1
J1
b e lo w
F2
G2
Tim e
Ra p id
spe e d
do wnwa rd
F3
G3
Slow speed upward
S ta rt
D elay
Press time 2
P re ssure
Press time 1
S ta rt by
S ig nal
IND E X on
Pressing speed downward
C2
Ra p id
sp e e d
up wa rd
Tim e
31
WALTEC
4.1.3.5
Screen Description: Pressing Cylinder B
F03 from Pressing cylinder A mask
2
C
D
E
F
G
J
K
L
4
3
Figure 8: Pressing cylinder B

Functions see Pressing cylinder A
32
WALTEC
4.1.3.6
Screen Description: Pressing Cylinder Curve
F04 from Pressing cylinder mask A and B
E
A
Figure 9: Pressing Cylinder Curve

Description of curve graphics
Horizontal axis = Time axis
Scaling of time axis by manual input of start value (A) and end value (B) of time. Just
tap onto the corresponding field and set the requested value.
Time measuring is starting together with the start of peripheral equipment, hence
starting of start delay of pressing cylinder. Any section from the cycle time of pressing
cylinder can be selected. By that, either the complete pressing cycle or also a given
section can be displayed with higher time resolution on the screen (zooming).
If the scaling of the time axis is changed, thus, a translation of the scanning rate is
effected in the control. Therefore the new time axis is only active after one or two
pressing cycles.
Besides the manual time scaling there is still the possibility of an automatic time scaling.
(see below).
Vertical axes = Speed/Position/Pressure
Display of pressing curve is two-channel type, i.e. two curves can be memorised at the
same time per cycle. Both channels can be scaled separately from each other.
Scaling is done by the input of a minimum (C, E) and maximum value (D, F). The
intermediate supporting points are calculated by the control unit. An alteration of the
scaling is immediately converted by the control and displayed as new curve, contrary to
the time scale.
For channel 1 the curve of the pressure-actual value is firmly conjugated. Concerning
channel 2 there can be chosen between 3 possible input values:
33
WALTEC
a)
Speed-actual value in mm/s
b)
Position-actual value in mm
c)
Pressure-set-point value in bar
The measuring units of the scaling are automatically shifted (mm/s, mm, bar).
Storing of a curve
One of the both active curves can be stored by means of key [F03] or [F04] and is
displayed visually as third curve. That means one is able storing a curve on the screen
for reference functions, and being able watching a possible variation concerning the
pressing curve, resulting by external influences. With [F5] the stored curve can be
deleted.
Activating / Deactivating of recorder
By means of the key [F07] the cyclic memorising of both measuring channels can be
started as well as stopped.
By pressing of [F07] "STOP" memorising gets inaccessible and it is appearing [F07]
"START". At the right screen "STATUS" there is appearing "STOP". If [F07] is once
more pressed, thus, there is appearing at [F07] "STOP" and at STATUS "ACTIVE". The
memorising of the measured values is once again released.
Automatic scaling of measured values
By the functions "scale at values 1" [F08] and "scale at values 2" [F09] the time raster
and with [F10] the scaling of the measured values is set by the control in such a way,
that the complete pressing cycle is getting visible on the screen.
For example, this function can be used at change-over of the production to another
article, seeing the complete cycle at first.
After that one is able scaling again a desired area manually
(time/position/pressure/speed) that details are getting visible.
34
WALTEC
4.1.3.7
Screen Description: Pressing Cylinder A/B
F04 from Basic mask
Figure 10: All pressing cylinders

With the button S14 all parameter of the pressing-cylinder A can be copied to B.
35
WALTEC.
4.1.3.8
Screen Description: Kick-out and blow out nozzle
F05 from Basic mask
Figure 11: Kick-out 1 and 2 and blow out nozzle

Function
Kick-out 1 and 2
Delay time
Time
Meaning
Kick-outs are pneumatic lifting devices which will lift articles in
mould to enable take out of articles.
Delay after indexing the rotary table in seconds before the kick-out
1 or 2 is actuated, e.g. 0.10s. The elapsing time can be observed to
the left after it has been started, e.g. 0.00s.
Time for the working stroke and dwell time kick-out, e.g. 1.00 s. The
elapsing time can be observed to the left after it has been started,
Step
e.g. 0.00s.
Displays the step of the program process. It is Important to search
for errors in the program. In the case of possible program failures
Residual time
Blow out nozzle
please forward the pertaining number to the WALTEC Company.

Pneumatic blow out noozle is used to clean the mould after article
take out to remove glass dust or broken glasses.
Table rounds on
Blow out can be adjusted to clean the moulds only after the table
turned some rounds to avoid to cool down the moulds too much.
36
WALTEC.
Function
Active
Only by glass
Meaning
Lamp will flash when pneumatic valve is actuated.
Blow out can be adjusted to clean only the moulds when broken
Alarm
glass has been detected by pyroscope or blow out nozzle can be

set to work continuously.
Attention: The speed of movement is set on both throttle non-return valves.

For reasons of time, the return movement of the cylinder should ensue as
quickly as possible and be throttled only for larger mould weights. The return
movement must always ensue so quickly that the kick-out has travelled in
before
the indexing table starts to move. The cylinder stroke can be
adjusted to upward direction with aid on a limit stop.
During set-up operation, the movement of the kick-out can also be controlled
via keys on the control cabinet.
37
WALTEC
4.1.3.9
Screen Description: Mould lubrication, Gob funnel, Cooling
F06 of Basic Mask
Figure 12: Mould lubrication, Gob funnel and Cooling

Function
Mould lubrication
Meaning
Kick-outs are pneumatic lifting devices which will lift articles in
mould to enable take out of articles.
Delay time
e.g. 0.00s.
Time
Step

Residual time
Gob funnel
Table rounds on

Pneumatic device which is used for centering gob in mould.
Mould lubrication can be adjusted to keep on lubricating the moulds
for some counts of table rounds.
38
WALTEC
Function
Table rounds off
Meaning
Mould lubrication can be adjusted to stop lubricating of the moulds
for some counts of table rounds.
Active
Cooling
Lamp will flash when pneumatic valve is actuated.

There are totally three cooling valves for cooling of article and
moulds.
With a three position-selector switch at the control panel can be
Article- and
mould cooling
outside
chosen one of the following modes: 1. Off; 2.Cyclical; 3. Continuous

In this mask can additionally be distinguished between Continuous
operation and Impulse. Continuous operation: Depending on the
selector switch the mode can be set (Cyclical or continuous
operation). Impulse: After the table-stop end the adjusted delayand dwell-time. As long as the dwell time remains, the Air flap is
opened
Mould cooling
inside
Flaps
Mould cooling after take-out: With a pre-selector at the control

panel the function can be turned on or off. In this mask can
additionally be distinguished between Continuous operation and
Impulse. Continuous operation: Cyclical mode; Air flap will only
close, if the table moves! Impulse: After the table-stop end the
adjusted delay- and dwell-time. As long as the dwell time remains,
the Air flap is opened.
With a pre-selector at the control panel all 6 flaps can be turned on
or off at once. Every single flap can also be chosen! Permanent
cooling: Cyclical mode; Air flap will only close, if the table moves!
Impulse: After the table-stop end the adjusted delay- and dwelltime. As long as the dwell time remains, the Air flap is opened.
39
WALTEC
4.1.3.10
Screen Description: Closer and Opener
F07 from Basic mask
Figure 13: Closer and Opener

Function
Pre-closer
Main-closer
Opener
Delay time
Time
Meaning
Pre-closer is a pneumatic actuated closing mechanism located at
the feeding position which is used when hinged moulds are
mounted and to close the moulds to allow feeding.
Main-closer is a pneumatic actuated closing mechanism located at
the pressing position which is used when hinged moulds are
mounted and to keep hinged mould closed while pressing.
Opener is a pneumatic actuated opening mechanism located
before or at the take-out position which is used when hinged
moulds are mounted and to open hinged moulds to allow take out
of articles.
e.g. 0.00s.
40
WALTEC
Step
Displays the step of the program process. It is used to locate

program errors. In the case of possible program failures please
Residual time
forward the pertaining number to the WALTEC Company.

see also Screen Description: Cycle time.
Attention: The speed of travel is set on both throttle non-return valves. For
reasons of time, the return movement of the pneumatic cylinder should ensue
as quickly as possible. The return movement must always ensue so quickly
that the device has travelled back before the indexing table starts to move.
Back position of devices is monitored by proximity switch. If these switches
are not actuated table is not allowed to move and a warning message will be
displayed like Pre-closer A monitoring!
41
WALTEC
4.1.3.11
Screen Description: Take-out HVM
F08 from Basic mask
Figure 14: Take-out device on press machine

Function
Take-out
Meaning
Rotating take-out device with two vertical axis (Arm1 and Arm2)
Pick up top
Pick up down
Slow up
used for taking out of articles. The arms can be moved separately.
Vertical axis positions can be shifted vertically by adding offset
value.
Initial position at the pick up position.
Pick up position of the glass article inside mould.
After picking up the article from the mould, the take out arm can be
Release ind.
table
slowly moved up, out of the mould.

If arm at the press machine is higher than this security position
than indexing table is allowed to move.
Offset Arm 1 / 2
Base position
Turn
Set down top
Set down down
Setpoint position of the turning axis for picking up of article. (The

take-out turning axis is moving 180 every cycle).
Speed, acceleration and deceleration setpoint for turning axis.
Initial position at the delivery position.
Delivery position of the article at the fire polishing machine.
42
WALTEC
Function (cont.)
Release glazer
Meaning
If arm at fire polishing machine is higher than this security position
following machine is allowed to turn or move!
Step
Displays the step of the program process. It is used for locating

program errors. In the case of possible program failures please
forward the pertaining number to the WALTEC Company.
4.1.3.12
Screen Description: Take-out Cam I HVM
F09 from Basic mask
Figure 15: Cam control 1 for Take-out device

Function
Take-out cams
Meaning
Electronic cams are used to control the movement of the servo axis
and of pneumatic valves.
Ind. Table move

Pick up arm down
Display of actual values of table movement.

Start of cam (positive edge) defines start of down movement of
servo axis at press machine. End of cam (negative edge) defines
start of up movement. For example: Arm will start to move down
when virtual axis position master take-out
43
WALTEC
Function (cont.)
Kick out up
Gripper closed
Meaning
Display of actual status (up / down) of kick out.
Cam defines when gripper (A1, A2, B1, B2) is closed.
Set-down arm
down
Start of cam (positive edge) defines start of down movement of

servo axis at fire polishing machine. End of cam (negative edge)
defines start of up movement. For example: Arm will start to move
down when virtual axis position master take-out.
Take-out turn
down
Gripper open
Start of cam (positive edge) defines start of turning movement of

servo axis. End of cam is only adjustable via indirect settings of
acceleration / deceleration.
Cam defines when gripper (A1, A2, B1, B2) will open.
Shift press / HVM

Act. position
master press
All cams (starts and stops) can be shifted by this value at once.
Display of actual value of virtual master axis of press machine.
Virtual master axis will turn from 0 to 360 in one production cycle.
Act. Position
Master take-out
Display of actual value of virtual master axis of take-out HVM. This

virtual master will trigger all actions.
4.1.3.13
Screen Description: Take-out Cam II HVM
F09 from Take-out Cam I mask
Figure 16: Cam control 2 for Take-out device
44
WALTEC
4.1.3.14
Screen Description: Fire polishing machine (FPM)
F10 from Basic mask
Figure 17: Fire polishing machine

Key overlay of this mask:
F1: Basic mask
F03: Blow Off / Blow Out
F04: Burner I
F05: Burner II
F06: Conveyor / Stacker
F07: Manual mode polishing machine
Function
Meaning
Step

Actual values for polishing machine position, spindle speed and
motor temperatures are displayed. If an electrical axis is still not
referenced, then actual position value will blink yellow / blue.
Actual values
v_max, a_max
actual speed and acceleration is displayed. If these values gets to

the limits an error message is displayed. Then reduce acceleration
and speed if possibly.
Function of FPM
There are two operating modes: 1) Gearing and 2) Table. Change

of operating mode is allowed only in manual mode of FPM.
45
WALTEC
Function (cont.)
Function of FPM
(continued)
Spindle per step

Spindle speed
Angular shift
Meaning
Gear: FPM will move with continuous speed. This mode should be
used when production speed is high.
Table: FBM will move according to adjustable cam. Start / stop or
fast / slow movement of spindles can be adjusted.
Number of spindles the pol. machine moves forward per cycle
(1, 2, or 3).
Initial position
Input of the override for the drive of the spindles [0..100%].

Aligning the rim polishing machine to the delivery position of the
master axis.
Aligning the rim polishing machine to the delivery position of the
Angle / position
acceleration
take-out device.
With this values the cam curve in this chart can be changed. The
maximum acceleration will be calculated automatically by the
control. The load of the machine can be decreased by setting a
lower value.
46
WALTEC
4.1.3.15
Screen Description: Fire polishing Blow Off & Blow out
F03 from Fire polishing mask
Figure 18: Fire polishing Blow Off & Blow out

Function
Distance
Meaning
Count how many spindles are between take out position and
position of blow off nozzle. Set this values according to count.
Start blow off
Position cam when blow off valve will be actuated. Max. value is
spindle distance = 241,5 mm.
When blow off cam is reached valve will be actuated impulse time
seconds.
Setting according to indexing table mould numbering.
Selection which article will be blown off of spindle. Used to sort
Impulse time
A-B
Select blow off
1,2,..12
Select blow off
article automatically according to quality. For example after mould

change.
All articles are blown off if button is selected.
1-12
47
WALTEC
4.1.3.16
Screen Description: Burner movement I (and II)
Figure 19: Burner movement I
Function
Actual values
Clutch position
Ramp
Stroke
Velocity / Accel.
position.
Meaning
Actual values for burner movement position, motor temperatures,
program step and so no are displayed. If an electrical axis is still not
Position of burner station (slide), where axis couples.
Defines, after how many millimeters the burner axis had to be
accelerated to the velocity of rim polishing machine.
Total stroke of burner slide movement.
Reversing velocity and acceleration of burner slide to the base
Base position
Spindle per step
Referred to measuring system of the burner slide.

Actual value how many mm FPM spindles will move per production
cycle. For example: 2*241.5mm = 483mm.
Synch. each
Spindle
Burner shift
Defines if burners are couples one each, or second or third spindle.

A small additional movement can be superposed to synchronous
movement.
48
WALTEC
4.1.3.17
Screen Description: Burner movement II
Figure 20: Burner movement II

If there are more burner slides at the machine, you will find a respectively number of
screen masks.
49
WALTEC
4.1.3.18
Screen Description: Cross conveyor & Stacker
Figure 21: Cross conveyor / Push bar stacker
Function
Meaning
Actual values
Cross conveyor
Function
Actual values for cross conveyor position, motor temperatures,

program step and so no are displayed. If an electrical axis is still not
Synchronous conveyor belt between FPM and stacker. Can be set
to three different operating modes: 1) move continuously or 2)
Velocitiy fast /
slow
clocked (with slow / fast speed) or 3) positioning mode.

Defines in clocked mode fast respectively slow speed of conveyor.
Cam start and stop angles will define when fast speed is active.
Velocity
Position
Accel. / Decel.
Defines speed of conveyor belt in continuous and positioning mode.

Defines distance belt moves per step in positioning mode.
Defines how fast belt will accelerate / decelerate. Adjustable from
[0..100%]. The higher the value the higher is acceleration / decel..
Push bar stacker Pneumatic stacker with two cylinders for forward / backward and up
/ down movement. Used for stacking of articles into cooling lehr.
50
WALTEC
Function (cont.)
Piece pushing
Meaning
Setting after how many production cycles (articles) stacker will be
actuated.
Staggered push.
If activated stacker will push articles each second time with 180
cam offset to allow higher packing of articles on cooling lehr.
Timer how long horizontal axis will move forward.
When articles are pushed in, stacker will move back as long this
Time forward
Time frontside
back
Time up
Time backward
timer is active. Used to prevent collision of bar with articles when

moving up.
Timer how long vertical axis will move up.
Timer how long horizontal axis will move back to base position. can
Start pusher
be decreased by setting a lower value.

Cam angle which defines when stacker will start pushing.
51
WALTEC
4.1.3.19
Screen Description: Manual polishing machine
F07 from Mask Fire Polishing machine
Figure 22: Manual Polishing machine

Function
Actual value
Position 1 and 2
Velocity
Meaning
actual position and motor temperature of all servo axis are
displayed.
Burner slide 1 and 2 maximum positions can be limited by setting
these positions (servo axis software limit).
Speeds can be set for all servo axis.
Actual values or output fields are mostly displayed in blue colour. Some
actual timing or position values are displayed in red colour. Setpoint values or
input fields are always in yellow colour with red background colour!
Position and speed settings made on the manual pages are only valid in
manual mode of polishing machine or press machine!
52
WALTEC
4.1.3.20
Screen Description: Additional functions
F11 of Basic Mask
Figure 23: Additional functions

Function
Additional funct.
Designation
Status
Counter
Meaning
Totally 10 digital outputs can be used for additional functions
needed.
Text field for adding a label to each digital output.
Display if output is activated.
When actual count reaches setpoint count function will be activated.
Delay time
Time
When function is activated, first the delay time must expire.

When delay time is expired, on timer will be started. As long this
timer is active as long digital output will be activated.
Preselect
Start options
Digital output can be switched on or off.

Defines condition when function will be started. Options are 1) start
signal from feeder, 2) start of indexing table or 3) stop of table.
Automatic / Cont.
Defines if digital output is always active continuously or if timer /

counter function is used in automatic mode.
53
WALTEC
4.1.3.21
Screen Description: MASTER AXIS
S05 from Basic Mask
Figure 24: Master Axis

Function
Master axis
Feeder impulse
Status
Int. clock
Linear shift
Meaning
Virtual master axis which gets synchronized to feeder by start
pulses from feeder.
There are two operating modes:
1) internal: virtual axis is freely running with speed set by
parameter int. clock
2) external pulse: virtual master axis gets synchronized by external
feeder impulse.
Display of feeder impulse
If PLC detects feeder impulse regularly a green hook will be
displayed to show that everything is fine. If no feeder impulse is
detected an exclamation mark will be shown!
Enter here the amount of cuts that the machine should perform if
the source is set to internal, e.g. 20,0 /min
Phase shift of the entire plant (press & fire polishing
machine) to the master axis (e.g. feeder)
54
WALTEC
Function (cont.)
Gobs per mould
Meaning
Depending on setting more gobs can be fed inside mould. Can be
used for example after job change to reheat the moulds quickly.
Actual speed
Actual position
Displays the speed of the machine in cycles/min.

Displays the actual position of the virtual master axis in
(synchronized with the external impulse or free-running).
For synchronisation to external impulse the actual positional
Positional
tolerance
Interface
Feeding active
variation will be displayed.

Display of signals which are exchanged between feeder and press
machine. Signals can be transferred by wire or by bus.
When feeder is actually feeding signals will be send to press.
Start from feeder

Press in feeding
position
Synchronization impulse from feeder send to press.

Signal to feeder that press can be fed with glass.
Press in STOP
Signal to feeder that press is in STOP condition and can not be fed
with glass.
Signal to feeder to increase gob weight.
Signal to feeder to decrease gob weight.
Glass level plus

Glass level minus
55
WALTEC
S09 from Master Axis
Figure 25: Master Axis Trace
56
WALTEC
4.1.3.22
Screen Description: Message display
S06 from Basic mask
Figure 26: Message display

Designation
Message text
Meaning
Actual messages or faults are always displayed below permanent
window. By tapping message text screen will open.
No.
Each message or error has a fixed number in the control. If you can
not solve problem by yourself, please always forward these
numbers to WALTEC and under what conditions problem occurred.
Display of time and date, when the incident has happened.
Each message or error will be indicated in their actual condition,
through:
Time and date

Status
Text
K
KQ
Description of the incident in a clear text.

Message arrived. The incident has taken place.
Message arrived and acknowledged by tapping ACK.
G
Background
colors
Message is gone. The incident has been removed or settled.

Operating messages are in yellow background color.
New arrived faults are in red color blinking.
Gone faults are in lightly red color.
Acknowledged faults are in white color.
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How to react if errors or faults are active and how to resolve them?
Most fault texts are self explaining but some are containing a reference
number, e.g. (14F1).
This number is a reference to an electrical device.
All devices and cables got a label and can be easily identified.
This number also is a reference to a page and column inside an electrical
draft.
First number tells you the page, the letter the kind of device (F = fuse) and
the last number tells you the column where you can find the faulty device
on the page.
Example:
Message text:
servo-hydraulic B: circulation pump bi-metal (14F1)
Error is related to servo-hydraulic system. Open page 14 column 1 of
electrical draft servo-hydraulic:
There you will find that motor protection switch 14F1 triggered.
Cause: Some over current problem for circulation pump B.
Remedies: Check cable, motor, setting of fuse 14F1 and fuse itself if its
switched on or off.
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4.1.3.23
Screen Description: Message archive
F03 from Message display
Figure 27: Message archive with printer function.
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4.1.3.24
Screen Description: CPU diagnosis cache
F04 from Message display
Figure 28: CPU diagnosis cache

In this screen the system messages of the CPU can be monitored.
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4.1.3.25
Screen Description: Data Record Processing
S07 of basic mask:
Figure 29: Data record processing on SD card

F01: Back to basic mask
F02: Store
F03: Input in controller
F06: Import Excel table
F07: Actual data export
F08: Export of all stored data
F10: Data delete
S09: Program information
In recipe field select and confirming.
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Data record name: Enter here the name of the data, which you wish to transfer, e.g.:
Feeder. You can also select a name from the contents.
F01: Back to the previous mask.
F02: Secures the actual data on the selected medium
F03: Data input from a medium into the memory of the machine controller
F06: Imports Excel table into data set.
F07: Exports the finally stored data as an Excel table in format CSV in a determined
destination directory of the optional server.
F08: Exports all stored data sets as an Excel table.
F10: Deletes selected data from the medium.
Attention: It is only allowed to put in data when the machine is running in manual
operation mode.
How to manage data sets on hard disc:
1. Storing a program
If you want to store data on the hard disc, enter a new name in the first line of the
screen (new data record).
You can enter letters and numbers for the program name.
After entering your desired name for the actual program data, push the ENTER
key to accept the name.
Now start transfer of data to the hard disc by pushing key F02
.
There will be a short message on the screen that confirms the action (success).
2. Loading a program
First you have to switch the machine to manual mode. It is not possible to load
another program during operation!
Move the cursor to the field data record name and push the ENTER key to get
a short list of all your programs.
Select the desired program by moving the cursor through the list.
To choose the highlighted program push the green ENTER key, the list will close
and the chosen program name keeps in the field.
.
Now push key F03
The program transfer to the PLC will start and a short message appears on the
screen.
Watch the message. If the transfer was successful, the actual program name will
be displayed in the first line of the permanent window of the screen. Go back to
the data screens (e.g. plunger curve) and look over the loaded data.
Now you can start production with the new loaded program!
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4.1.3.26
Screen Description: Program information
S08 from Basic mask
Figure 30: Program information

For all programs you can write, store and retrieve important notes (for example article
data etc.) with the help of this mask.
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4.1.3.27
Screen Description: Mould selection
S09 from Basic mask
Figure 31: Mould selection

Function
Select 0-6-12
Meaning
By setting this touch-button to all moulds (12), half of the moulds (6)
or no mould will be selected (0).
On / off touch-button for selecting / deselecting each individual
mould.
Display which mould is selected.
On / off touch-button for selecting which article processed in which
mould will be blown off on fire polishing machine.
Select
Active
Reject
Reject all
Mould by select.
On / off touch-button for selecting if all articles are blown off on

FPM. Used after job change to sort out low quality articles.
Actual processed mould at press station.
If a mould has been switched off, the mould will remain active until it
reaches the mould select station. Station mould select can be set on the
Indexing Table screen (S09 from Basic mask).
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4.1.3.28
Screen Description: Glass thickness measuring
S13 from Basic mask
Figure 32: Glass thickness measuring
Function
Glass thickness
Meaning
Depending on setting glass thickness will be controlled differently.
1) Glass thickness measuring PC A to plunger A/B:
Measurement of pressing cylinder A only will control plunger A and
B of feeder.
2) Glass thickness measuring PC B to plunger A/B:
Measurement of pressing cylinder B only will control plunger A and
B of feeder.
3) Glass thickness measuring PC A/B separately:
Each plunger A or B will be controlled by assigned pressing cylinder
A or B.
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F05 from Glass thickness measuring
Figure 33: Glass thickness measuring A
Function
Meaning
Set-point
Actual value
Enter the desired value here.

Displays the current value.
Threshold max.
If upper threshold is reached signal is send to feeder to reduce gob

weight.
Threshold min.
If lower threshold is reached signal is send to feeder to increase

gob weight.
If this thresholds are exceeded control of gob weight needs to be
readjusted. First manually weigh gob weight. If not o.k. adjust gob
weight by lifting up / down the tube mechanically. If after some time
Maximal reset /
minimal reset
Scaling
Alarm
gob weight is nearly fine press touch-button Glass thickness o.k..

Now automatic gob weight control will be in control again (but
selector-switch on feeder panel must be ON!)
Scaling of graphical display.
Acoustical alarm signal can be switched on or off. Can be used to
alarm operator to readjust gob weight by hand.
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4.1.3.29
Screen Description: Mould Temperature
S14 from Basic mask
Figure 34: Mould Temperature
Function
Meaning
Mould temp.
This is an overview of all moulds. The actual measured value is

written into the memory field for the corresponding mould every time
a mould is located under the pyrometer. Optionally a threshold can
be defined.
A fault is written into the mould register for the mould in subject if
the measured temperature value exceeds the threshold and if the
function moulds monitoring is selected. This entry initiates that this
mould is not processed for one round (indexing table).
With F04 you can see the mask Mould temperature trace (see
Delay evaluation
next page). There you can select a mould and the corresponding
graph for the temperature profile of the last hour will be shown
When indexing table stops this delay time is started. When time
elapsed temperatue is measured by pyroscope mounted above the
mould. Pyroscope must be adjusted by laser pointer to point
correctly inside mould.
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Function (cont.)
Actual mould
Actual value
Max
Min
4.1.3.30
Meaning
Actual mould measured is displayed.
Actual temperature of mould. On left side are moulds A. On right
side are moulds B.
Threshold value. If actual temperature is higher than threshold than
internal PLC-register for this mould will be set that according to
setting on indexing table page mould will not be fed / pressed
anymore.
Threshold value. If actual temperature is lower than this threshold
than another internal register will be set. Depending on this register
the mould can be processed differently.
Screen Description: Mould Temperature Trace
F04 from Mould Temperature
Figure 35: Mould Temperature Trace

Function
Trace
Meaning
Display of average temperatures of all moulds.
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4.1.3.31
Screen Description: Residual time
S15 of Basic Mask
Figure 36: Residual times

In this mask the cycle times of several devices will be displayed. Actual times and
residual times are displayed. The maximum allowed cycle time (dwell time) is displayed
on top. This time corresponds approximately to stop time of the indexing stable. As long
as the indexing table is not moving peripherial devices can access the table without risk
of collision. If the peripherial device (like pressing cylinders) takes too long to finish its
process then indexing table is forbidden to move. Whole production process will be
disturbed. So it is very important that all process times are not longer than the maximum
allowed cylcle time. Also because of jitter and small process variations the residual time
should not be to close to zero seconds.
Green bar means: The cycle time for the movement of the peripheral is shorter, than
the movement cycle starts new. The remaining time (positive value) is displayed behind
every bar.
Red bar means:
The cycle time for the movement of the peripheral is longer, than
the movement cycle starts new. This results in an stop of the press with an error
message .... Monitoring and Indexing table starts to early! Workaround: Extend the
time or raise the speed for this periphery! The remaining time (negative value) is
displayed behind every bar.
No bar means:
periphery not selected in the working cycle!
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Figure 377: Normal process with positive residual time
Figure 388: Interrupted process for one cycle with negative residual time
Function
Cycle time
Indexing time
Dwell time
Meaning
time for one production cycle, e.g. 20 pieces/min -> 3.00 seconds.
time indexing table needs from start to stop of indexing, e.g. 1s
time indexing table is stationary, e.g. 3 s -1 s = 2 seconds.
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4.1.3.32
Screen Description: Faults Sinamics
S17 from Basic mask
Figure 39: Faults Sinamics

From this picture, you can read the faults and the fault text of the electrical axes. If it is
not automatically reset, you must eliminate the faults and acknowledge the message
with ACK. In order to acknowledge you must switch to operating mode MAN.
Faults of axis will be displayed in form of normal text.
If an error occurs, the screen shows an icon at S10 in each mask, when pressed you
will be forwarded to the mask Faults SINAMICS.
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F04 from Faults Sinamics I
Figure 40: Faults Sinamics II

If there is a servo axis fault, please follow procedure below:
For example: Cross conveyor got fault [F] and warning [W] (see Figure 38 above).
Fault number:
Fault text:
F 31885
Warning number:
Warning text:
W 7454
Encoder 1 DRIVE-CLiQ (CU): Cyclic data transfer error
LR: Position actual value preprocessing does not have a valid encoder
Now tap on icon F6 which will open PDF-documentation for Sinamics S120 drives.
Search in documents for Fault 31885 and Alarm W 7454 and you will find this error
description:
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As you can see in the last section there is always a list of remedies.
And because there is no communication between Control Unit and Encoder, document
suggests to:
- check the power supply voltage
- carry out POWER ON
- replace the component involved (cable, encoder, CU).
In our case encoder cable had been damaged or disconnected.
So after replacing or reconnecting problem should be solved. Maybe (depends on fault)
POWER ON will be necessary.
This warning (or alarm) has been also related to disconnected or damaged encoder
cable. Actual position of encoder cross conveyor could not be read.
With very high probability faults can be found outside electrical cabinet. First
at all try to locate damaged, burned (hot glass1) or disconnected cables.
Replace them if necessary. Only in case of main power faults (e.g. because
of lightning strikes) check also for faults inside cabinet.
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F05 from Faults Sinamics I
Figure 41: Faults Sinamics III
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4.1.3.33
Screen Description: Service
S18 from Basic mask
Figure 42: Service

Password protection:
Some screen masks are restricted for special users, like maintenance or service
technicians. For getting access, the user has to put in a password. If user and password
agree with each other, it is possible to get access to these settings.
By typing standard code 100 and confirming it with ENTER , you can select various
masks with the aid of the screen via the function keys.
Important Note: During set-up of the machine/device all
machine data are set by the service engineers of the
WALTEC Company. Even after the machine/device has been
handed-over to the user, the machine data may be changed
only by personal, trained by service engineers of the WALTEC
Company!
Key overlay of service mask:
F01: Return to basic mask
F02: Status-Profibus
F03: Machine data indexing table
F04: Machine data pressing cylinder
F05: Machine data Scaling analogue input
F07: Machine data Sinamics

F08: Status Sinamics
F09: Status Infeed
F10: Status CU320
F11: Status TM31
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F06: Limitation
S01: TRACE S7
S02: Machine Data burner LINDE
S03: Reset counter
S04: Login
S05: Logout
S06: Password list
S07: Message display
S08: Machine Data read in / read out
F12: Keyboard
S09: Lubrication
S11: Status / control
S12: Management date and time
S13: Status of digital inputs/outputs
S15: Lamp check
S16: Language selection
S17: Faults Sinamics
S18: Cooling indexing table
Actual values or output fields are mostly displayed in blue colour.

Some actual timing or position values are displayed in red colour.
Setpoint values or input fields are always in yellow colour with red
background colour!
If actual values are displayed like this ##### then value is too big
to be displayed or communication between panel and PLC is
interrupted!
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4.1.3.34
Screen Description: Status Profibus
F02 from Service mask
Figure 43: Status Profibus

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

A time of breakdown will be indicated.
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4.1.3.35
Screen Description: Machine data indexing table press
Figure 44: Machine data indexing table press

Danger: All data should only ever be changed by personal, trained
by service engineers of the WALTEC company! Improper changes
may lead to personal injury and serious machine damage!
Function
Machine data
Maximum number
of moulds
Calculated step
width
Acceleration
Torque standstill
Indexing cylinder
before table start
Override table
Meaning
Parameters related to indexing table are listed and can be
modified. If an electrical axis is still not referenced (homed), then
actual position value will blink yellow / blue.
Depending on table mechanic different count of maximum moulds
can be set, e.g. 12 moulds or 6 moulds.
Full turning of table is 360 divided by 12 moulds are 30 step
width per mould..
Max. acceleration and deceleration of servo motor indexing table
can be reduced. Motor current is proportional to acceleration.
When motor is in position, torque is reduced automatically.
Before indexing table starts index cylinder will be actuated not to
block table turning.
Speed of indexing table in manual mode will be automatically.
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Function (cont.)
manual mode
Index
Periphery start
Motor current
Payload
Meaning
reduced to 10% of maximum speed.
Value after which the indexing cylinder engages depending on the
override setting of the indexing table drive in automatic mode.
Value after which the periphery is started depending on the
override setting of the indexing table drive in automatic mode.
Actual value of motor current is displayed. Actual motor torque is
always proportional to actual motor current and acceleration.
If because of high payload the positioning accuracy of indexing
table motor gets worse (position overshooting), just increase slider
value to reduce position overshooting.
If because of very high payload of indexing table (very heavy

moulds and / or fast indexing of table) motor current gets to the
maximum limit, just reduce current by reducing maximum
acceleration / deceleration of motor!
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4.1.3.36
Screen Description: Machine data pressing cylinder A
Figure 45: Machine data for pressing cylinder A

Danger: All data should only ever be changed by personal, trained
by service engineers of the WALTEC company! Improper changes
may lead to personal injury and serious machine damage!
Function
Machine data
Start up
commissioning
Circulation pump
Encoder
System pressure
Maximum system
pressure
Minimum system
pressure
Meaning
Parameters related to pressing cylinder servo hydraulic A (B) are
listed and can be modified.
Page is used at initial commissioning (start up) of servo hydraulic
system. Tap on start up function inactive to activate / deactivate
commissioning.
Circulation (cooling) pump can be switched on / off. Status of pump
and minimal pressure switch is displayed
For position measurement of hydraulic cylinder a linear absolute
value encoder with SSI-interface is used. When cylinder is in top
most position actual position of encoder must be set to zero by
tapping zero.
Actual value of system pressure (input pressure of hydraulic
pump).
System pressure should not exceed upper limiting value of 10 bar.
System pressure should not exceed lower limiting value of 2.5 bar.
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Function (cont.)
Filling pump on
Filling pump off
Monitoring time
Maximum stroke
Maximum
pressure
Maximum velocity
Relief after
pressing
Actual values
Setpoint values
Meaning
If actual system pressure falls below 3 bar filling pump is switched
on automatically.
If actual system pressure is higher than 3 bar + 0.3 bar filling pump
is switch off automatically.
When filling pump is activated timer is started. When timer elapsed
and setpoint pressure is not reached an alarm is generated.
Maximum possible stroke of pressing cylinder, e.g. 500 mm.
Maximum allowed hydraulic pressure of pressing cylinder, e.g. 300
bar.
Maximum speed of pressing cylinder according to production data,
e.g. 830 mm/s.
When timer is elapsed pressure is relieved.
Actual position, pressure, speed, oil and servo motor temperature
are displayed. Actual values are displayed in blue colour.
Setpoint for speed and pressure of pressing cylinder are set.
Setpoint values or input fields are always in yellow colour with red
background colour.
For first commissioning and filling or refilling of system with oil or
pump replacement see documentation servo hydraulic
Voith_Servohydraulik_Befllanleitung_EN.pdf.
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F04 from Machine data pressing cylinder B
Figure 46: Machine data for pressing cylinder B
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4.1.3.37
Screen Description: Machine data Scaling analogue input
F05 from Service Mask
Figure 47: Scaling analogue input

Attention: All data should only ever be changed by personal,
trained by service engineers of the WALTEC company! Improper
changes may lead to personal injury and serious machine
damage!
Function
Scaling
Minimum
Maximum
Actual value
Meaning
Used to adapt input voltage or current of analogue input module to
PLC internal parameter.
Analogue input signal, like mould temperature or temperature of
indexing table rotor, must be scaled using a minimum and
maximum parameter.
Actual temperatures (if correctly scaled) of moulds and rotor of
indexing table are displayed
Mould temperatures below 100C can not be measured with
pyroscope.
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4.1.3.38
Screen Description: Limitation
F06 from Service Mask
Figure 48: Limitation
Function
Limitations
Maximum speed
Acceleration
Actual value
Gearing factor
Select drive
direction
Meaning
The maximum speed and the maximum acceleration can be
entered on this mask, which dependents on the physical condition
of the drive. This is performed by the WALTEC company at startup. These values refer to the actual resulting speed and
acceleration of the axis depending on the current cycles. This
means that the current cycles are included into the calculation and
is compared with the limits when the plunger curve is changed. An
error message appears on the mask and the last loaded curve is
activated should the set limits be exceeded.
Definition of the maximum allowed traveling speed of the servo
axis.
Definition of the maximum allowed acceleration of the servo axis.
Actual speeds and accelerations.
Parameter to adjust speed of spindle turning. When setpoint speed
of spindle turning fire polishing machine is set to zero this
parameter has to be adjusted until spindle stops turning.
In case of blockage of fire polishing main drive (for example chain
is blocked because of glass pieces). By selecting Select VM Jog
reward in manual mode chain of main drive can be moved back to
be able to remove blockage.
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Max. sinus
position
When polishing machine is in mode sinus and defining cam for

sinus-movement, setting of position can be limited by this value.
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4.1.3.39
Screen Description: Machine Data SINAMICS
Figure 49: Machine data SINAMICS

Attention: All data should only ever be changed by personal,
trained by service engineers of the WALTEC company! Improper
changes may lead to personal injury and serious machine
damage!
Function
Machine data
Reference point
coordinate
Reference point
shift
Jog velocity
New ref. point
Zero encoder
Meaning
Parameters for incremental (relative) encoders and servo axis.
After power off or motor replacement all servo motors containing
relative encoders will loose its actual position and needs to find
(home) reference point again! If an electrical axis is still not
referenced (homed), then actual position value will blink yellow /
blue.
In ref.-mode (homing) axis is looking for reference point signal then
stops and sets current position to this parameter.
In ref.-mode (homing) axis is looking for reference point signal then
stops moves this distance and then sets actual position value
When axis is not referenced this parameter defines how fast axis
will move.
If new ref. point is tapped, axis can be referenced again.
For position measurement of hydraulic cylinder a linear absolute
value encoder with SSI-interface is used. When cylinder is in top
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most position actual position of encoder must be set to zero by

tapping zero enc.
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4.1.3.40
Screen Description: Status Sinamics
Figure 50: Status Sinamics

Function
Status Sinamics
Axis
Drive actual
values
IN
J_FWD
J_BWD
OUT
FWD
BWD
ARFD
FAULT
WARN
Meaning
On this page actual values, basic control and status bits of all
Sinamics drives can be monitored. Used for diagnosis of servo
drive.
Tap on selection box to select Sinamics drive.
Actual values for position, speed, motor temperature, motor
current, output voltage and DC link voltage are displayed.
Actual control bits are displayed, like:
Jog forward
Jog backward
(for more information, check Sinamics documentation).
Actual status bits are displayed, like:
Axis is moving forward
Axis is moving backward
Axis is referenced (homed)
Axis is in fault state
Axis is in warning state
(for more information, consult Sinamics documentation).
Selection box options Axis:

Indexing table (torque motor)
Take out turning (torque motor)
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Take out arm 1 (servo motor)

Take out arm 2
Fire polishing main drive
Fire polishing table rotation
Fire polishing burner stroke 1
Fire polishing burner stroke 2
Cross conveyor
Pressing cylinder A
Pressing cylinder B
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WALTEC
4.1.3.41
Screen Description: Status Infeed
Figure 51: Status Infeed
Function
Status infeed
Control word
Status word
Actual values
Meaning
On this page actual values, basic control and status words of all
infeed modules be monitored. Used for diagnosis of infeed
modules.
Control bits send from PLC to infeed module.
Status bits send from infeed module to PLC.
Actual value for frequency, input voltage, current, active power and
module temperature is displayed.
Selection box options Status Infeed:

Infeed 1
ALM (Active line module = infeed) of press machine
Infeed 2
ALM of servo hydraulic system
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4.1.3.42
Screen Description: Status CU320
Figure 52: Status CU320

Function
Status CU320
Utilization
Meaning
Status of digital inputs and outputs of Control Unit 320 can be
monitored. Not all signals are connected to PLC-I/O-modules.
Some signals related to motion control (reference point switches,
hardware limit switches), emergency stop, start impulses, cams
and so on are connected directly to I/O of the control unit CU320
CPU utilization in [%]. If too close to 100% no additional code or
drive can be added which can be controlled.
Selection box options Status CU320:

Control unit 1
CU indexing table
Control unit 2
CU take out turning and arm 1 and 2
Control unit 3
CU fire polishing, table rotation and burner movem.
1
Control unit 4
CU burner movement 2 and conveyor
Control unit 5
CU for pressing cylinder A
Control unit 6
CU for pressing cylinder B
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4.1.3.43
Screen Description: Status TM31
Figure 53: Status TM31
Function
Status TM31
Meaning
Status of digital I O and analog inputs of Terminal Module 31 is
displayed. Not all signals are connected to PLC-I/O-modules.
I/O-Signals related to servo hydraulic system are connected to
terminal modules TM31 inside cabinet of servo hydraulic.
Selection box options TM31:

TM 31_A 1
First TM31 module of press cylinder A
TM 31_A 2
Second TM31 module of press cylinder A
TM 31_B 1
First TM31 module of press cylinder B
TM 31_B 2
Second TM31 module of press cylinder B
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4.1.3.44
Screen Description: Trace S7
S01 from Service Mask
Figure 54: Trace S7

Function
Trace S7
F02
F03
F04
F05
F06
Meaning
Can be used to sample and visualize graphically PLC data of all
kind. Channels, sampling time, interval and trigger must be
selected.
Visualize 4 channels at the same time.
Defines trigger parameter.
Defines data channels being sampled
Scale min and max value of y axis channel 1 automatically
Scale min and max value of y axis channel 2 automatically.
Example:
Actual position of indexing table drive is stored in database DB81.DBD36. When motor
is running flag M103.0 is active. This flag can be used for triggering starting of sampling
of motor position indexing table.
In picture above channel 1 (blue curve) has been used for sampling of motor position.
Scaling of y-axis maximum value is set to 60000 which means 60.000.
Sampling interval is set to 6000 which means 6000ms = 6.000seconds.
You can see that table turned two times 30.
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How to set channel and trigger parameter?

Function
Channel
Area
Data type
DB-Nr.
Byte, Bit
Selection
Average
Function
Trigger
Area
Data type
DB-Nr.
Byte, Bit
Actual value
Sampling period
Cyclic
Trigger condition
Trigger threshold
Meaning
Maximum 4 channels can be used for data
sampling. Here we use channel 1.
Selector if Database (DB), Input (I), Output
(O) or a Memory-flag (F) will be sampled.
Selector if DWORD, WORD, BYTE, BIT will
be sampled.
Defines data base number being sampled.
Depending on selection above Byte and or
Bit-number must be chosen.
To activate sampling.
To activate average value sampling.
Meaning
Signal used for starting of sampling.
Selector if Database (DB), Input (I), Output
(O) or a Memory-flag (F) will be used for
triggering.
Selector if DWORD, WORD, BYTE, BIT will
be used as trigger parameter.
Defines data base number
Depending on selection above Byte and or
Bit-number must be chosen.
Actual trigger value can be monitored.
Interval how long data will be sampled.
Maximum 64 seconds are possible
If activated sampling is cyclic.
Conditions can be set which must be fulfilled
to start sampling.
Threshold value which must be exceeded to
start sampling.
Conclusion:
Sampling is started when trigger value is smaller than 1, in other
words when motor stopped.
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4.1.3.45
Screen Description: Machine Data burner LINDE
Figure 55: MADA burner LINDE

Function
Linde burners
Select
Enable signal
Delay burner off

Enable
Meaning
Can be used to change settings for machine parameter for LINDE
burners. Totally adjustments for four burners can be made.
Three different settings are available:
1) Enable signal continuous: Burners will be always switched on.
2) Enable signal when station is on: Burners will be only switched
on if station or device is enabled.
3) Enable delayed burner switch off, when section is off: If burner
section is disabled then burners will be switched off after delay
time.
Option 2 and 3 can be used to save gas and / or oxygen.
Option 3 can be used to make fine adjustment regarding delayed
switch off of burners.
Delay time can be adjusted by setting input field delay burner
off.
Will flash in green colour when burner is active
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4.1.3.46 Screen Description: Mada Record Processing

S08 from Service Mask:
Figure 56: Mada record processing

F01: Back to basic mask
F02: Store machine parameter
F03: Read machine parameter
F06: Import Excel table
F07: Actual data export
F08: Export of all stored data
F10: Delete machine parameter
In recipe field select by pressing in the required line and confirm with the ENTER key.
For example to store the machine data, first enter name MADA in input filed
New Data Record then press ENTER and finally press F02 to store parameter.
For example to read machine data, choose parameter file in input field Data Record
Name and then press F03.
Important: Data can be read only in manual mode! Also machine
parameter should be changed only by WALTEC staff. Please
contact WALTEC staff if parameters need to be changed, for
example if they have been deleted accidentally.
97
WALTEC
4.1.3.47 Screen Description: Lubrication

Figure 57: Lubrication

Function
Lubrication
Counter
Impulse
Meaning
Oil quantity for press and polishing machine can be adjusted. Too
less oil will increase friction and wear of machine parts.
Amount of cuts after lubrication will be started, e.g. 500 pieces.
The amount of the already processed cuts can be read in the front
of the field, e.g. 198.
Lubrication duration in seconds, e.g. 2.00s. Status of valve and
pressure switch are displayed. Lubrication valves can be actuated
manually by pressing softkey valve on.
Note: Set the impulse duration at least so long that the lubrication
pump can totally complete its cycle, otherwise a sufficient lubrication
cannot be guaranteed! On manometer oil pressure must be higher
than approximately 60 bar.
4.1.3.48 Screen Description: Management date and time

98
WALTEC
Figure 58: Management Date / Time

Function
Date and time
S7 CPU time
Windows time
Set time
Meaning
Used for synchronizing of PLC time with panel time.
Internal date and time of programmable logic controller (PLC).
Internal date and time of operator panel
Input fields for entering actual date and time
S18Touch-button for synchronizing PLC and panel time.
99
WALTEC
4.1.3.49
Screen Description: Status digital inputs
Figure 59: Status digital inputs

Function
Status digital
inputs
Meaning
Status of digital inputs of programmable logic controller. Page can
be used to monitor digital inputs of PLC. Only 4 X 8 bits can be
displayed at the same time.
Selection box options of input range:

Input 0.0 -3.7
Input 4.0 -7.7
Input 8.0 -11.7
Input 12.0 -15.7
Input 16.0 -19.7
Input 20.0 -23.7
100
WALTEC
4.1.3.50
Screen Description: Status digital outputs
F04 from Status digital inputs
Figure 60: Status digital outputs

Function
Status digital
outputs
Meaning
Status of digital outputs of programmable logic controller. Page
can be used to monitor digital inputs of PLC. Only 4 X 8 bits can
be displayed at the same time.
Selection box options of output range:

Output 0.0 -3.7
Output 4.0 -7.7
Output 8.0 -11.7
101
WALTEC
4.1.3.51
Screen Description: Status analogue inputs
F05 from Status digital inputs
Figure 61: Status analogue inputs

Function
Status analogue
inputs
Meaning
Page can be used to monitor the state of analogue inputs of PLC.
If there is an over range condition colour of bar will change from
blue to red (see picture above).
102
WALTEC
4.1.3.52
Screen Description: Cooling indexing table
S18 from Service mask
Figure 62: Cooling for indexing table (torque-) motor

Function
Cooling indexing
table motor
Meaning
Machine parameter for cooling of indexing table torque motor can
be set and actual temperatures monitored. Depending on
temperatures warning and alarms are generated.
Cooling pump on
Setpoint value for the motor temperature, at which the cooling
pump will be switched on.
Hysteresis
This value is deducted from the value Cooling pump on, to
ensure stable running of the pump. Example: 55 3 = 52C at
52C the pump is switched off.
Cooling pump off if Actual temperature of the rotor (the magnets) IR must not be
more than the set value higher than the actual temperature of the
stator (the coils) KTY.
Example: Set value 20C. Rotor temperature must not be more
than 20C higher than the stator temperature.
If this setpoint value is reached, the cooling is switched off, to
avoid rotor touches stator.
103
WALTEC
4.1.3.53
Screen Description: Trace temperature
S18 from Cooling indexing table
Figure 63: Trace temperature

Function
Trace
Meaning
Temperature recording of actual temperature of stator coils (KTYsensor) and rotor (Infrared-sensor). Also influx and reflux
temperature of cooling liquid are recorded. Finally status of pump
(on/off) will be recorded too.
104
WALTEC
4.1.3.54
Screen Description: Status / Control
S11 from Service mask
Figure 62: Status / Control
Danger: Changes to the PLC internal data should only ever be

made by service engineers of the WALTEC Company! Improper
changes may lead to personal injury and serious machine damage
Function
Connection
Type
DB-Nr.
Offset
Bit
Data type
Format
Status value
Meaning
Submenu with the selection of the PLC
Submenu with the selection of DB, I, O, F, T, C
Input of the desired data block
Start address of I, O, F and data DBW, DBD, DBB
Bit of start address I, O, F and data DBW, DBD, DBB
Selection of the desired types of the dates: BIN, HEX, DEC
Selection of the: CHAR; WORD; INT; DWORD; DINT; REAL
Actual value
Note: There is the possibility of the observation of the status values
up to the individual bits. Even control of each individual bit would be
possible.
105
WALTEC
Turning on the Machine and Set-up Mode

Attention: A back-up on the flash with the machine data, axis data, and
production programs must be established after set-up. The functionality
of this flash must be checked immediately. For emergency cases it is to
be stored in a safe, for storage media appropriate area.
Attention: In the case that machine or axis data must be read into the
machine, the machine must be restarted in order for the data to be
loaded into the machine controller.
Attention: Program data may only be read into the machine while the
machine is in a standstill condition. Axis and machine data are only
stored again, if the program was changed by the supplier!
The following switches and keys are to be operated for switching on:
1.
Set switch "MAN-AUTO-REF" to manual.
2.
Set main switch(es) on side or in front of control cabinet to "I".
3.
Push "Emergency off Reset" key. All Emergency off keys have to be
unlocked!
4.
Approaching of reference points

For axes with limited stroke or rotation such as take-out or turning
device: Move the axes with the manual push-buttons to the coloured
markings or markers for basic setting (not necessary for endless axes).
Attention: The axes must be moved one after another to the markers
so, that no collision with any machine parts can occur. No safety locks
are provided!
Turn switch MAN-AUTO-REF to REF =reference point.
Press reference point push-button
When the reference point is reached the lamp in the reference point
push-button does not longer flash and the corresponding message
disappears from the screen.
5.
Turn switch MAN-AUTO-REF back to MAN =manual operation.
106
WALTEC
Reference: If the machine is operated in normal operation, before

approaching the reference points a limit switch limiting the movements of
an axis can be approached. To travel away from the limit switch the reset
button of this axis inside the control box or at the control panel must be
pushed and at the same time the corresponding directional push-button.
Machine is ready for manual operation. All keys and switches usable for manual
mode can be operated.
On safety grounds, the set-up motions are controlled not via Simatic, but via
relays. The relays are not actuated in automatic mode.
The hydraulic set-up motions and the servo axes stop immediately when the
button is no longer pressed.
Danger: Pneumatic actuated movement is completed after actuation of

button!
107
WALTEC
Initial Position and automatic operation
6.1
Initial Position
The machine is to be operated in the initial position with the manual function
push-buttons. The operating messages show which component groups are not in
initial position, as soon as you switch over to automatic operation. It is only
shown for components which are switched in.
All cylinders and adjustment parts of the machine must be set according to the
needs of production.
6.2
Engagement of Automatic Mode

Switch to automatic mode (AUTO).The machine initiates automatic mode with the
1st starting pulse from the feeder or robot (ball gatherer) or in general the
upstream machine or plant.
If the machine remains stationary after the 1st machine cycle, it is to be checked
on the basis of operating messages and the observation of the production
whether e.g. the starting pulse has arrived prematurely.
Not all assemblies must be switched in at engagement of automatic mode. It can
be switched in only as required by manufacturing sequence.
6.3
Monitor circuit
The machine is monitored automatically so that collision movements of important
functions cannot occur in automatic mode.
When monitor responses (displayed by a message at the screen) and the
machine stops, check which function has failed. The concerning limit switch was
not reached, or is defective, wrongly assembled or the cable to the limit switch is
defective.
To eliminate malfunction switch machine over to manual mode. After elimination
automatic mode can be reengage.
108
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6.4
Settings in automatic mode

In automatic mode, all values available for alteration can be altered on the
operator panel. Choose the needed field in the screen and alter the required
value.
The cylinder strokes are altered on the machine itself through adjustment of limit
switches or through adjustment of the limit stops. The machine cycle can thereby
be adapted to change operating conditions.
6.5
Running Machine Empty and Shutting off

When last glass article has been fed in and last operating process has been
completed shut off all devices you don't need anymore.
When you want to run machine empty, shut off feeding machine, for example
Gob Feeder, Loading machine or Input Conveyor. When last article has been
taken out from machine shut off all devices (0-I Switches to 0) and then change
over from automatic to manual mode. Switch off all motors and at last main
switches.
6.6
Malfunction in Automatic Mode and EMERGENCY OFF

If a part has not been removed from the mould or cullet is located inside the
mould, for example the pressing cylinder, the indexing table, or the take-out can
be switched off via mushroom buttons on the machine. All other machine
functions continue to run. Through actuation of the small button located to the
mushroom button, the blocked function can be released.
Danger: If you want to work on the facility you switched off with "STOP"
or you work in the danger area of the facility you must shut off also with
pre selection switch "0-I".
If malfunctions occur in automatic mode, these are indicated in the fault field of
the VDU and can be corrected. The indicated error messages has to be deleted
with the yellow ACK key in manual mode, after the malfunctions are eliminated.
Reference: If the error message of an electric axis is not deleted, it can't

be moved.
109
WALTEC
Emergency-off
Through actuation of the red emergency off button, the machine is immediately
stopped, all motors are switched off and the control system is isolated from the
machine. To restart the machine in automatic mode, the machine must be
restarted as described under point Switching Machine on for Manual Operation
.
110
WALTEC
6.7
Malfunctions and their Rectification S7-300

Most machine malfunctions are indicated via display.
Other malfunctions should be localized as follows:
Open control cabinet
Check whether the green Run LED shows clearly. Switch on CPU module
must stand on position RUN. If the lamp does not show, check on the
terminal strip whether the 24 V supply voltage is available. If available check if
the LED DC 5V shows. If not exchange power supply module.
Check whether the red SF LED shows. If yes, see operating manual of
Control S7-300.
If individual functions are not controlled in automatic mode, the machine remains
in automatic mode. On the basis of the circuit diagram, the number or the
relevant output is sought and the output modules checked as to whether the
green LED indicates that the output is controlled. If automatic operation is not
possible, it can be checked via manual operation whether the function is
executed or whether the output is controlled. If the output is controlled, the cable
to the assembly and the appropriate part are to be functionally checked.
During manual action, the functions are switched via relays. On the basis of the
circuit diagram, it is to be checked whether the appropriate relay switches
through or sticks.
In automatic operation the functions are released also by relays, check also
these.
Danger: During all operations in the control cabinet, on the terminal

boxes, and on the external electrical parts, other than test operations
with test appliances by an expert the main switch is to be switched off.
111
WALTEC
6.8
Overall Reset of the control S7-300

If the yellow "STOP" LED on the central processing unit (CPU) shows although
the CPU mode selector is set to "RN" (run) position, you must overall reset the
internal memory.
Proceed as described in Operating manual of Control S7-300.
The Step7 program is loaded automatically after successful "Overall Reset" from
the plugged EPROM module.
After Overall Reset you must load the program data from the flash into the
internal memory.
112
WALTEC
Adjustments when Changing an Axle Drive
7.1 Necessity for Approaching the Reference Point

Because of the use of resolvers in the positioning component group, once the
power supply is switched off the computer loses its current position. When the
power supply is turned on again the reference point must be located in order to
permit a later absolute positioning in automatic operation. It is only after the
approaching of the reference point that the indicated required position value
tallies with the absolute required position of the axle in question with reference to
its zero-point.
113
WALTEC
7.2 Approaching the Machine Reference Point

Within the possible process range, one machine reference point is defined and
retained permanently per axle in order to synchronise the computer with the
mechanics. For the rotary distance measuring resolver one cam is evaluated
(roughly) and one "zero point" (finely) for the resolver.
The reference point is selected in such a way that it can be found quickly and
easily after switching on. After starting the procedure for finding the reference
point, the cam is started with a contact-free limit switch at a fixed, preprogrammed speed. The "zero-mark" is approached, and if necessary displaced,
at a second speed. The reduction cam is connected via a rapid input on the front
side of the positioning component group.
Reference: If you have an axle drive with Torquemotor (direct rotation

drive of indexing table of the glass press) approaching the reference point limit
switch will be inapplicable and the "zero- mark" will be approached immediately.
The relocation of the reference point can be defined with machine date (MD)
Reference point
Zero mark of
resolver
1 revolution of
resolver
Cam
Signal of limit
switch
Travelling
speed of axis
Machine
zero point
Ref. point
shift
Figure 64: Reference point location
114
WALTEC
7.3 Calculating the Reference Point Displacement

The unit of displacement is to be entered in millimetres for linear axes and for
round axes in degree. The plus or minus sign shows the direction of the
displacement of the reference point.
If a motor is replaced or the axis taken to pieces mechanically, the reference
point must be calculated again:
a) If it is still possible, the machine zero point must be measured and noted
before the motor is replaced. All positioning values relate to this machine zero
point. If this is no longer possible the old machine zero point must be found
with the aid of a clearly marked point with known coordinates (e.g. a marking
on the mechanics).
b) Replacement of the drive element if necessary.
c) Switch on the computer and select operating mode MAN. In the machine
data picture at the service level the machine data reference point must be set
to zero (=> machine zero point the same as the zero mark) on the axis in
question.
d) Select operating mode REF., so the machine data are transferred again.
Approach the reference point by pressing the key for the concerning axis. The
axis will now stop shortly after leaving the cam on the zero mark of the
resolver.
e) Select manual operation (MAN). Measure the distance from the axis to the
old machine zero point, or approach the machine zero point with the function
keys and read the value off from the mask. Enter this value in the machine
data reference point, using the plus or minus sign to show the direction of the
displacement of the zero point. If the machine zero point is unknown and some
other clearly marked point is being used, the difference must be calculated
{known coordinate value minus value actually existing} and entered into MD.
f) Switch the whole installation off and on again. Approach the reference point
and check, adjust again if necessary. The installation is now ready for
operation again.
115
WALTEC
Index
1st machine cycle ............................. 108
automatic mode ........................ 108, 109
control cabinet .................................... 19
control cabinet .................................... 20
cooling unit ......................................... 19
Data record processing ................ 61, 97
electric axis ....................................... 109
emergency off ................................... 110
emergency off key ............................ 106
initial position .................................... 108
malfunctions ..................................... 109
malfunctions S7-300 ......................... 111
monitor.............................................. 108
mushroom button.............................. 109
operator panel .................................. 109

over voltage protection ....................... 19
positioning component group............ 113
pre selection switch .......................... 109
reference point.................................. 114
Reference point ................................ 114
reference point displacement............ 115
reference points ................................ 106
resolver ............................................. 113
run machine empty ........................... 109
safety locks ....................................... 106
switching on ...................................... 106
zero point .......................................... 114
Figures
Figure 1: SIMATIC IPC277 ............................................................................................ 21
Figure 2: Basic Mask ..................................................................................................... 22
Figure 3: Manual mode settings for pressing cylinder and take out ............................... 24
Figure 4: Indexing Table 1 ............................................................................................. 26
Figure 5: Indexing Table 2 ............................................................................................. 27
Figure 6: Info about indexing table registers .................................................................. 28
Figure 7: Pressing cylinder A ......................................................................................... 29
Figure 8: Pressing cylinder B ......................................................................................... 32
Figure 9: Pressing Cylinder Curve ................................................................................. 33
Figure 10: All pressing cylinders .................................................................................... 35
Figure 11: Kick-out 1 and 2 and blow out nozzle ........................................................... 36
Figure 12: Mould lubrication, Gob funnel and Cooling ................................................... 38
Figure 13: Closer and Opener ....................................................................................... 40
Figure 14: Take-out device on press machine ............................................................... 42
Figure 15: Cam control 1 for Take-out device................................................................ 43
Figure 16: Cam control 2 for Take-out device................................................................ 44
Figure 17: Fire polishing machine.................................................................................. 45
Figure 18: Fire polishing Blow Off & Blow out................................................................ 47
Figure 19: Burner movement I ....................................................................................... 48
Figure 20: Burner movement II ...................................................................................... 49
Figure 21: Cross conveyor / Push bar stacker ............................................................... 50
Figure 22: Manual Polishing machine............................................................................ 52
Figure 23: Additional functions ...................................................................................... 53
Figure 24: Master Axis ................................................................................................... 54
Figure 25: Master Axis Trace......................................................................................... 56
Figure 26: Message display ........................................................................................... 57
Figure 27: Message archive with printer function. ......................................................... 59
Figure 28: CPU diagnosis cache ................................................................................... 60
Figure 29: Data record processing on SD card.............................................................. 61
Figure 30: Program information ..................................................................................... 63
Figure 31: Mould selection............................................................................................. 64
116
WALTEC
Figure 32: Glass thickness measuring........................................................................... 65

Figure 33: Glass thickness measuring A ....................................................................... 66
Figure 34: Mould Temperature ...................................................................................... 67
Figure 35: Mould Temperature Trace ............................................................................ 68
Figure 36: Residual times .............................................................................................. 69
Figure 377: Normal process with positive residual time................................................. 70
Figure 388: Interrupted process for one cycle with negative residual time .................... 70
Figure 39: Faults Sinamics ............................................................................................ 71
Figure 40: Faults Sinamics II ......................................................................................... 72
Figure 41: Faults Sinamics III ........................................................................................ 74
Figure 42: Service ......................................................................................................... 75
Figure 43: Status Profibus ............................................................................................. 77
Figure 44: Machine data indexing table press ............................................................... 78
Figure 45: Machine data for pressing cylinder A............................................................ 80
Figure 46: Machine data for pressing cylinder B............................................................ 83
Figure 47: Scaling analogue input ................................................................................. 84
Figure 48: Limitation ...................................................................................................... 85
Figure 49: Machine data SINAMICS.............................................................................. 87
Figure 50: Status Sinamics ............................................................................................ 89
Figure 51: Status Infeed ................................................................................................ 91
Figure 52: Status CU320 ............................................................................................... 92
Figure 53: Status TM31 ................................................................................................. 93
Figure 54: Trace S7 ....................................................................................................... 94
Figure 55: MADA burner LINDE .................................................................................... 96
Figure 56: Mada record processing ............................................................................... 97
Figure 57: Lubrication .................................................................................................... 98
Figure 58: Management Date / Time ............................................................................. 99
Figure 59: Status digital inputs .................................................................................... 100
Figure 60: Status digital outputs .................................................................................. 101
Figure 61: Status analogue inputs ............................................................................... 102
Figure 62: Cooling for indexing table (torque-) motor .................................................. 103
Figure 63: Trace temperature ...................................................................................... 104
Figure 64: Reference point location ............................................................................. 114
117

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WALTEC

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

Operating Manual - Electronic Control Press line,z-en.doc

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

Operating Manual - Electronic Control Press line,z-en.doc

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

FUNDAMENTAL SAFETY INSTRUCTIONS

Warnings and symbols

Basic operation and designated use of the machine/plant

Selection and qualification of personnel - Basic responsibilities11

Warning of special dangers

Mobile machinery and equipment

ELECTRONIC LOGIC CONTROLLER

STRUCTURE OF CONTROL CABINET

DESCRIPTION OF THE FUNCTIONS IN THE CONTROL CABINET20

Screen and keyboard

Operating Manual - Electronic Control Press line,z-en.doc

Screen Description: Take-out Cam I HVM

TURNING ON THE MACHINE AND SET-UP MODE

INITIAL POSITION AND AUTOMATIC OPERATION

Engagement of Automatic Mode

Operating Manual - Electronic Control Press line,z-en.doc

Settings in automatic mode

Running Machine Empty and Shutting off

Malfunction in Automatic Mode and EMERGENCY OFF

Malfunctions and their Rectification S7-300

Overall Reset of the control S7-300

ADJUSTMENTS WHEN CHANGING AN AXLE DRIVE

Necessity for Approaching the Reference Point

Approaching the Machine Reference Point

Calculating the Reference Point Displacement

Operating Manual - Electronic Control Press line,z-en.doc

Foreword to the operating instructions

Operating Manual - Electronic Control Press line,z-en.doc

Fundamental safety instructions

1.1 Warnings and symbols

Reference (refers to special information on how to use the

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

1.2 Basic operation and designated use of the machine/plant

Operating Manual - Electronic Control Press line,z-en.doc

1.3 Organisational measures

Operating Manual - Electronic Control Press line,z-en.doc

Operating Manual - Electronic Control Press line,z-en.doc

Operating Manual - Electronic Control Press line,z-en.doc

1.4 Selection and qualification of personnel - Basic responsibilities

Operating Manual - Electronic Control Press line,z-en.doc

1.5 Safety instructions governing specific operational phases

Operating Manual - Electronic Control Press line,z-en.doc

Operating Manual - Electronic Control Press line,z-en.doc

1.6 Warning of special dangers

Operating Manual - Electronic Control Press line,z-en.doc

Gas, dust, steam and smoke

Hydraulic and pneumatic equipment

Operating Manual - Electronic Control Press line,z-en.doc

Oil, grease and other chemical substances

1.7 Mobile machinery and equipment

Operating Manual - Electronic Control Press line,z-en.doc

Operating Manual - Electronic Control Press line,z-en.doc

Electronic logic controller

Structure of control cabinet

Attention: Change filter mats in regular intervals. Keep cabinet

Operating Manual - Electronic Control Press line,z-en.doc

Attention: Maximum temperature of environment for cabinet with

Description of the Functions in the Control Cabinet