manual12
DESCRIPTION
TRANSCRIPT
FB TR1860 L1/6
use and service manual
serial no. 740
F.B. Balzanelli avvolgitori spa w ww.fb-balzanelli.it20158 milano Via Teglio, 11 Tel. 02.603572 Fax 02.603342 e-mail: [email protected]
61030 Borgaccio di saltara (Pu) Via Buonarroti, 11 Tel. 0721.892168 Fax 0721.879602 e-mail: [email protected]
FB TR1860 L1/6
Use and service ManualSerial No. 740
TR1860 L1/6
Serial No. 740Client UPONOR A/S
Code FB01061700SA740/mnDate 10.05
OVERVIEW
As well as using the machine correctly, the operators should carefully read and fully understand this user manual and
strictly follow the instructions it contains. Spending some time reading this manual will allow health and safety risks to people
and financial losses to be avoided.
For the entire life of the machine, the manual should be kept in a location easily accessible to all operators and maintenance
engineers.
Purpose of this manual
This manual is supplied as part of the machine and has been written by the manufacturer to supply all the information
required to those who are authorized to work with the machine.
This manual describes the machine as it was at the time of publication and cannot therefore reflect any information
whatsoever on future or non standard products.
The accuracy of the information given in this manual and its conformity with the equipment described is correct at the time of
printing. However, possible differences may still be present.
F.B. Balzanelli Avvolgitori SpA is fully committed to continuous technological development of its machines and therefore
reserves the right to make changes or improvements to its products at any time.
No part of this manual may be reproduced or transmitted to third parties in any form or by any means, electronic or mechanical
or otherwise, without the prior written permission of F.B. Balzanelli Avvolgitori SpA.
All products or registered marks listed in this manual belong to their respective owners
Manual Layout
Apart from any differences which do not affect the accuracy of the information provided, this manual is divided into four
parts.
The first part, the introduction, contains all general health and safety information.
The second part contains the information on the coiling machine and its components.
The third part of the manual contains the information on the software supplied with the machine.
The last part is a practical guide on how to use the coiling machine.
FB TR1860 L1/6
Index
Part I
SAFETy AND gENERAL INFORMATION
Part II
MACHINE INSTALLATION AND FUNCTIONINg
Part III
SOFTWARE USER MANUAL
Part IV
PRACTICAL gUIDE TO THE USE OF THE COILER
Part V
TECHNICAL ATTACHMENT
Use and Service Manual
Serial no. 740 - 10.05
FB TR1860 L1/6 Part ISaFeTy aNd geNeRaL INFoRMaTIoN
1. Rules . . . p. II
2. Machine manufacturer identification . . . p. II
3. Coiler description and use . . . p. III
4. Not allowed uses . . . p. III
5. Dangerous areas . . . p. IV
6. Safety devices. . . p. V
7. Acoustic and luminous indicators . . . p. VII
8. Safety general rules . . . p. VIII
9. Glossary . . . p. X
10. Symbols . . . p. XI
Use and Service Manual
Serial No. 740 - 10.05
Part I Safety and general information
FB TR1860 L1/6 RULeS
1. Rules
The coiler has been conceived and realised in compliance with the standards established by the European harmonised
rules - EN Rules. Thus, it meets the requirements required by the Italian law and the European Directives relating to the
production of machines. In particular:
PublICATIoN ARGuMENT DATE
Regulation 89/392/CE on machine manufacturing 14/06/1989
Regulation 91/368/CE (modified with the 89/392/CE) 20/06/1991
Regulation 93/44/CE (modified with the 89/392/CE) 14/06/1993
Regulation 93/68/CE (modified with the 89/392/CE) 22/07/1993
Regulation 98/37/CE (modified with the 89/392/CE) 22/06/1998
CEI EN 60204-1 • CEI EN 60204-2 Machine safety - Machine Electric equipment
2. MACHINe MANuFACTuReR IDeNTIFICATION
The following identification tag is applied on the electrical control panel of the machine.
logo
Address identification of the Constructor
Machine Model
Machine number
Manufacture year
Conformity CE symbol
Use and Service Manual
Serial No. 740 - 10.05 2
Part I Safety and general information
FB TR1860 L1/6 USe
3. COIleR DesCRIpTION AND use
The TR1860 is an automatic machine for industrial use for the winding and packaging of corrugated pipes made of plastics. It
realizes coils having variable characteristics according to the data selected by the operator, packaged with 3 or 6 binding
points with thermo-welded polypropylene strap.
ThE fuNCTIoNING of ThE CoIlER DuRING ThE PRoDuCTIoN CyClE IS CoMPlETEly AuToMATIC.
The intervention of the operator is required only for the initial preparation of the machine, according to the characteristics of the
pipe to wind, the coils to realize and to solve eventual functioning anomalies.
The coiler cannot be used to produce coils for manual strapping.
The intervention of the operator is required only for the initial preparation of the machine, according to the characteristics of
the pipe to wind, the coils to realize and to solve eventual functioning anomalies.
The automatic functioning of the machine is controlled by a PlC (Programmable logic Control), an electronic device
which can be programmed for the management and control of the production processes, and that uses a f.b. balzanelli
Avvolgitori SpA original software, which is specific for this model of coiler.
for further information on the programme, please refer to the third part of this manual.
The operator drives and controls the functions of the PlC by means of a local PC equipped with a display and a
keyboard placed on the Control board. The PlC directly manages, or by means of further devices (axis controls,
activations for electric motors, pneumatic electro valves), the operations of the different actuators of the machine.
4. NOT AllOweD uses
f.b. balzanelli Avvolgitori SpA could not be held responsible of the damages caused by an incorrect use of the machine or by
a service not correctly carried out.
IT IS AbSoluTEly foRbIDDEN ANy oThER uSE of ThE MAChINE oThER ThAN ThE oNE SPECIfIED.
Use and Service Manual
Serial No. 740 - 10.05 3
Part I Safety and general information
FB TR1860 L1/6 daNgeRoUS aReaS
5. DANgeROus AReAs
here follow the areas where the operator can stay during the functioning of the machine and those where the stay is forbid-
den.
Aluminium and polycarbonate structure
Aluminium and polycarbonate structure
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Part I Safety and general information
FB TR1860 L1/6 SaFeTy devIceS
6. sAFeTy DevICes
D A N g e R - A T T e N T I O N
Tempering wiTh and/or removing The safeTy devices from The coiling machine may
compromise operaTor’s safeTy.
emergency mushroom buttons pneumatic valveby pressing this button, the machine Placed inside the pneumatic cabinet,immediately stops in emergency. The it allows you to disconnect the
main buttons is placed on the electricalpanel, the other four are placed in four
different points of the machine
photocell BarriersWhenever there is an obstacle along
the trajectory of at least one of the twopairs of photocells, the machine stopsimmediately in the emergency state
Use and Service ManualSerial No. 740 - 10.05
machine from the pneumatic supplyline by discharging the residual energy
Main switchAllows the machine to be disconnected from
the electrical power supply.The switch is located on the front of the
electrical control panel
5
Part I Safety and general information
FB TR1860 L1/6 SaFeTy devIceS
The coiler is equipped with a protection device from the mechanical and electrical risks.
All the moving mechanical parts are placed in a cage made of aluminium sections and polycarbonate.
opening the access doors (safety barriers) during machine operation will immediately stop the coiling machine, which cannot be
restarted until the doors have been closed again.
D A N g e R - A T T e N T I O N
The safeTy barriers may be disabled by inserTing The key provided in The elecTrical conTrol
panel (see picTure) (on=1). This condiTion is conTinually shown by a blue warning lighT (see
paragraph 7).
The key used To disable The safeTy barriers musT be kepT by The safeTy manager.
D A N g e R - A T T e N T I O N
accessing The inside of The coiling machine wiTh The safeTy barriers disabled is only
allowed To qualified sTaff.
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Part I Safety and general information
FB TR1860 L1/6 acoUSTIc aNd LUMINoUS INdIcaToRS
7. ACOusTIC AND luMINOus INDICATORs
D A N g e R - A T T e N T I O N
Tampering wiTh and/or removing These Two signalling columns fiTTed To The coiling machine
may impair The correcT operaTion of The machine and increase The risk To The operaTor
An acoustic and visual indicators column is pla-
ced on the upright of the pipe guide.
A. Acoustic signal A
It indicates the starting up of the coiler by means B
of the button AIR RESET.
C
The signalising goes on for 5 seconds, after
then the machine will be pneumatically supplied.
Should you be inside the coiler and hear the
acoustic signalising, press immediately one of
the stop buttons placed on the columns of the
coiler or on the keyboard.
b. yellow light
It indicates the presence of alarms or a coiling stop caused by an anomaly. Check the kind of alarm on the operator’s terminal. A
selector on the operator panel permits associating an audible alarm with the visible alarm.
C. blue light It indicates the DISAblING of the protection bars, when the key placed on the electrical panel has been turned on oN =1.
D A N g e R - A T T e N T I O N
if necessary, before inTervening inside The elecTrical cabineT, cuT The Tension by operaTing on The power swiTch placed in The elecTrical panel. To enTer The elecTrical cabineT, open The door by means of The suiTable key kepT by The Technical responsible.
A second column fitted with visual indicators is
located on the upper section of the rear of the
coiling machine, near the coil exit side
D. blue light It indicates the expulsion of the coil from the Dcoiler and stays on all the time that is necessary
for the expulsion.
be very careful because from the lighting of the
blue indicator the photocell is disabled.
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Part I Safety and general information
FB TR1860 L1/6 SaFeTy geNeRaL RULeS
8. sAFeTy geNeRAl Rules
The manufacturer, during project and construction, has paid particularly attention to those aspects which can cause risks to the
safety and health of the people who interact with the machine. further to the respect of the relating laws in force, he has
adopted all the rules of the good technique of construction. The aim of this information is to make the users aware about
paying a particular attention in order to avoid all risks.
however, the most important thing is to operate with caution. Safety also depends on all the operators who interact with
the machine.
Read carefully the instructions reported in the manual supplied with the machine and the instructions directly applied on
the machine; in particular, it is necessary to respect the instructions relating to safety.
Do not alter, eliminate or by-pass the safety devices installed on the machine. If this instruction is not respected, this can
cause serious risks to the safety and health of people.
The personnel who carries out any type of intervention during the whole life of the machine, must have special technical
competencies, particular capacities and a know how and experiences in the specific sector. The lack of these require-
ments can cause damages to the safety and health of people.
During the normal use or for any intervention on the machine, keep the perimetrical spaces in safe conditions, in order
not to cause risks to the safety and health of people. for some phases it could be necessary the aid of one or more
assistants. In these cases, it will be necessary to train and inform them about the kind of activity to carry out in order not
to cause damages to the safety and health of people.
The operator must be informed about the use of the machine and must have capacities and competencies related to the
kind of the activity to carry out. Even after being suitably informed, at the first use of the machine, if necessary, simulate
some test operations in order to identify the commands and their main functions.
use the machine only for the uses foreseen by the manufacturer. The use of the machine for improper uses can cause
risks to the safety and health of people and economic damages.
The machine has been conceived and manufactured in order to meet all the operational conditions indicated by the manu-
facturer. Altering any device to obtain performances other than those foreseen can cause risks for the safety and health
of people and economic damages.
Do not use the machine with the safety devices non perfectly installed and efficient. The non respect of this requirement
can cause serious damages for the safety and health of people.
Keep the machine in conditions of maximum efficiency by carrying out the programmed service operations indicated by
the manufacturer. A good service will allow you to obtain better performances, a longer time of exercise and a constant
level of the safety requirements.
before carrying out any service and adjustment intervention on the machine, activate all the safety devices and evaluate
if it is necessary to inform the personnel who operates on the machine and the personnel nearby. In particular it is neces-
sary to signal the nearby areas and avoid the access to all those devices which could, if activated, cause sudden danger
conditions by causing damages to the safety and health of people.
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Part I Safety and general information
FB TR1860 L1/6 SaFeTy geNeRaL RULeS
The service and adjustment intervention must be carried out by authorized people, which must prepare all the necessary
safety conditions according to the procedure indicated by the manufacturer.
All the service intervention requiring a special technical competence or particular capacities must be carried out only by
qualified personnel having a know how and experience in the specific intervention. In order to carry out service interven-
tions in those areas which are not easily accessible or dangerous, prepare all the suitable safety conditions for everyone
in compliance with the law in force relating to the safety in the work areas.
Replace the used particulars by using original spare parts. use oils and greases suggested by the manufacturer. All this
could ensure the functionality of the machine and the foreseen safety level.
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Part I Safety and general information
FB TR1860 L1/6 gLoSSaRy
9. glOssARy
operator:
a person who has been chosen and authorized among those who have the requirements, the
competencies and the necessary information relating to the use and ordinary service of the machine or of
the installation in object
person charged of the service:
a technician who has been chosen and authorized among those who have the requirements to carry out
the interventions of ordinary and extraordinary service on the machine or on the installation in object.
he/she must have certain information and competencies with particular capacities in the intervention
sector
installer:
a technician chosen and authorized by the manufacturer or his mandatory among those who have the
requirements in order to carry out the installation and the test of the machine or of the installation in
object
responsible of the installation:
a technician chosen and authorized to organize all the organization and operational aspects of the
personnel working at the installation and charged of the production activities
assistant:
a subordinate person assisting the production activity of the machine or of the installation in object
ordinary service:
all the necessary operations in order to keep the good functioning and efficiency of the machine or of
the installation in object. Generally, these operations are programmed by the manufacturer who defines the
necessary competencies and the intervention modalities
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Part I Safety and general information
FB TR1860 L1/6 SyMBoLS
10. syMBOls
In order to outline some parts of the text which are particularly important or to indicate some important specifications, some
symbols, whose meaning is described below, have been adopted.
Interventions which can be carried out only by the personnel charged of the service.
D A N g e R - A T T e N T I O N
iT indicaTes siTuaTions of greaT danger ThaT, if noT Taken inTo consideraTion, can cause
serious damages To The safeTy and healTh of people.
C a u t i o n - p r e c a u t i o n
it indicates that it is necessary to adopt special rules in order not to cause damages to the safety and health of
people and economical damages.
I n f o r m a t i o n
It indicates technical information which are particularly important.
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FB tR1860 l1/6 Part IIMachIne InstallatIon and FunctIonIng
1. Coiler installation . . . .21.1 Technical data and perimetric areas. . . 21.2 Overall dimensions . . . 31.3 Transport and handling . . . 41.4 Unloading and positioning. . . 51.5 Removal of blocks for transport . . . 61.6 Assembling the shields . . . 71.7 Main power supply line connections . . . 8
2. operation, adjustments and Control . . . ...102.1 Machine main parts. . . 102.2 Automatic functioning . . . 112.3 Operating cycle stage description. . . 112.4 Pipe-guide Unit . . . 12
2.4.1 Mechanical adjustments . . . .132.4.2 Pneumatic adjustments . . . ..142.4.3 Adjustments of the pipe guide by the Operator panel. . . ...15
2.5 Reel Unit . . . 162.5.1 Functioning . . . ..172.5.2 Mechanical adjustments . . . .182.5.3 Pneumatic adjustments . . . ..212.5.4 Adjustments of the reel from the Operator panel . . . ...22
2.6 Strapping machine and Strap unwinding machine . . . 232.6.1 Functioning . . . ..242.6.2 Strap introduction or change . . . .252.6.3 Pneumatic adjustments . . . ..272.6.4 Adjustments of the strapping machine by Operator panel . . . ..282.6.5 Adjustments by operating on the electrical board . . . ...282.6.6 Sealing blade replacement . . . ..29
2.7 Command Panel . . . 302.7.1 Operator’s terminal . . . ..302.7.2 Additional buttons . . . ...312.7.3 Damper battery replacement . . . .32
3. maChine starting up and stop . . . ..333.1 Machine starting up. . . 333.2 Machine stop caused by an emergency device (mushroom shaped emergency button) . . . 343.3 Machine stop caused by the opening of the safety barriers or by the stop button. . . 353.4 Switching the machine off . . . 36
4. serviCe . . . .374.1 Ordinary service general indications. . . 374.2 Materials supplied . . . 394.3 Spare parts . . . 394.4 Consumption materials . . . 404.5 Machine dismantling . . . 40
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Part II Machine installation and functioning
FB tR1860 l1/6
1. Coiler installation
1.1 technical data and perimetric areas
description
Type of coilable pipe
Coilable pipe diameter (*)
Reel flange diameter (coil maximum external diameter)
Minimum and maximum width between reel flanges (coil width)
Reel drum minimum and maximum diameter (*)
Recommended strap (W x T)
Strap coil internal diameter
Strap coil external diameter
Strap coil height
Length
Width
Height
Total weight
Number of strapping machines
Number of strapping operations
Number of reels
Control
Input voltage
Average power consumption
Start up current
Installed power
Compressed air operating pressure
coIleR InstallatI n
Features
Corrugated
16-20-25-32-40-50-63 mm
1860 mm
150÷450 mm
400÷1500 mm
12 x 0,8 mm
200 mm
400 mm
190 mm
7400 mm
3750 mm
2950 mm
11.000 kg (ca)
1
3 - 6
2
PLC
3~ + N / CA 380V +Earth
11 A
32 A
6 kW
0,6 .. 0,7 MPa
(*) Warning: the range of coilable pipes and the coil diameter achievable with a single machine depend onwhat was agreed at the time of ordering.
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Part II Machine installation and functioning
FB tR1860 l1/6
1.2 overall dimensions
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coIleR InstallatI n
7400
21003750
3
o
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Part II Machine installation and functioning
FB tR1860 l1/6
1.3 transport and handling
d a n g e r - a t t e n t i o n
coIleR InstallatI n
in order to reduCe the risk oF tilting, the liFting oF the Coiler by means oF a Crane
should be Carried out by qualiFied personnel
C a u t i o n - p r e c a u t i o n
taking into consideration the complexity and dimensions of the machine, you should define at the moment of the
contract, the responsibilities and modes to handle, install, and carry out the final test. those who carry out these
operation should previously organize a “safety plan” to safeguard the health of the people concerned and, if
necessary, should organize a training for the operators charged of the use of the machine.
Lifting with crane It is possible to lift the coiler up by means of a crane as shown in the figure, by fixing the special ropes on the suitable
openings placed in the frame of the machine.
Back charging bands
Place the pipe guide in the central position with the lowered
vertical axis.
Front charging bands
Hooking rings
Before charging, verify the block of all the moving parts by means of the
suitable mechanical red stops (see 1.4).
Use the charging bands in the 4 points of passage indicated in the drawing
The fore bands must be longer than the back ones. If they are not available,
use some hooking rings to reset the required charging conditions
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Part II Machine installation and functioning
FB tR1860 l1/6coIleR InstallatI n
o 1.4 unloading and positioning
C a u t i o n - p r e c a u t i o n
it is suggested to make the F.b. balzanelli avvolgitori spa qualified personnel carry out the installation and
test the machine.
position the machine on an even floor suitable to withstand heavy loads.
To rest the machine on the floor,
use the lugs provided at the bottom
of bedplate (a).
A A
A
Check with a spirit level that the machine is perfectly flat.
If necessary, adjust the threads on the rubber feet to stabilise and
balance the machine.
The distance between the coiler and the pipe output point from the extrusion line must range between 5 and 10 m.
For a better functioning of the system, it is recommended that the coiler longitudinal axis lines with the pipe to wind
point.
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Part II Machine installation and functioning
FB tR1860 l1/6
1.5 removal of blocks for transport
coIleR InstallatI n
To avoid dangerous mouvements and damages during transport, some mechanical blocks are applied to the moving parts of the
coiler. Identify all the red stops applied to the moving part and remove them as indicated in the figures.
binding of the moving parts
cut the eventual bands which blocks the mechanical particulars pipe guide translation block
indentify on the pipe guide group one or more red mechanical blocks (A) and remove them reel moving basement translation stop
identify on the moving basement of each reel one or more red mechanical blocks and completely remove the screw (B). strapping machine feeding stop
identify in the front or back part the mechanical blocks (C) and remove them.
a b
C d
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Part II Machine installation and functioning
FB tR1860 l1/6
1.6 assembling the shields
coIleR InstallatI n
The shield are not assembled on the machine as delivered. Certain safety precautions must be observed in order to guarantee the
safety of the personnel operating the machine.
The shields must be assembled on the coiler as soon as it has been positioned. Never start the machine if the shields are not in place.
Do not replace the original machine shields with different barriers and/or materials.
The mounting brackets must be fitted both on the right (see picture), and on the left hand side of the machine (the
fitting location for the mounting brackets on both sides is identical). These mounting brackets are provided to fasten the
safety barriers by means of screws inserted in the central holes (see picture).
The operator should pay special attention to the connections between the mounting brackets and the safety
barriers as the latter must be firmly fastened to avoid any problems arising during the coiling machine working cycle.
Regularly check that the mounting bracket, the safety barriers and the bedplate are firmly fastened.
Brackets
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C
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Part II Machine installation and functioning
FB tR1860 l1/6
1.7 main power supply line connections
Electrical supplyConnect the coiler to an electrical line at 380/400V
alternating current (3 phases + 1 neutral + 1 earth) by using an
anti-flame cable in compliance with the rules in force, having
a minimum section of 25 mm2. Carry out a connection which
is able to support a maximum absorption of 64A.
Pneumatic supply
coIleR InstallatI n
C
Connect the machine to a compressed air line supply by means of a pipe having a diameter of 12 mm.
Use an exercise pressure ranging between 0,6 ÷ 0,7 mPa by means of the pressure adjuster (a) placed outside the
pneumatic board. (see image). AThe coiler is equipped with two filters (a drier filter and an extracting oil filter) for the collection of the condensate and oil on the
supply circuit having micro-pores of different sections, both filters are eBuipped with a float for the automatic discharge (b). thus,
it is suggested to check that the level of condensate does not exceed the indicated one.
The plant of air treatment is equipped with a progressive starting up electrically activated valve (C).
C
A
B
A
B
C
i n f o r m a t i o n A
if the compressed air general supply circuit of the plant produces too much condensate, it is suggested to
install a dryer device upward the coiler or at the outlet of the compressor.
B
C a u t i o n - p r e c a u t i o n
do not use lubrication oil for cylinders on this machine; if necessary install a lubricating device downward the
condensate filters and use esso nuray 32
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Part II Machine installation and functioning
FB tR1860 l1/6
Telephone connectionFit a phone doubler with RJ11 (a) C coupler to provide a
direct phone line with the factory in order to seek remote
technical support with F.B. Balzanelli Avvolgitori SpA
engineers, if required (For more information, see Part III
“Software User Manual”).
Before seeking remote technical support, connect the
phone cable to the RJ11 (b) modem connector, as
shown in the picture.
Check that the modem on/off switch (C) is pressed.
i n f o r m a t i o n
coIleR InstallatI n
A
B
C
For each assistance request, communicate the data reported on the identification tags (see part i - paragraph 2)
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Part II Machine installation and functioning
FB tR1860 l1/6oPeRatIon, adjustMents and contR l
2. operation, adjustments and Control
2.1 machine main parts
D C
B
G
ref. part
a reel 1
b reel 2
C strapping machine
d pipe guide
E F
A
desCription
Pipe coiling devices
Coil strapping device on both reels
Pipe guide device during coiling
e electrical/pneumatic control panel Cabinet containing the electrical and pneumatic components
F operator’s terminal Data visualization and introduction device
g slides Devices for the expulsion of the coiled coils
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Part II Machine installation and functioning
FB tR1860 l1/6
2.2 automatic functioning
oPeRatIon, adjustMents and contR l
The pipe, exiting from the extrusion line, is manually introduced by the operator in the oscillating arm device.
This has the function to detect the tension of the pipe, between the extrusion line and the coiler, in order to adjust automati-
cally the coiling speed. Always manually, the pipe is introduced in the pipe guide device which will hook it in the first reel that
has received the authorization to run. From this moment on, operation is fully automatic. Principal phases of operation:
2.3 operating cycle stage description
stage desCriptoion
1 hooking the pipe guide moves to a position suitable for hooking the pipe on the first reel readyfor the coiling phase. Pipe hooking onto the reel is fully automatic
2 Coiling the reel begins to rotate
at every turn of the reel, the pipe guide translates laterally by a length equal to the
diameter of the pipe
reel rotation terminates when the number of turns or meters of pipe set by the operator
has been reached
3 paddle approaChing once coiling has been completed, the reel spattles move toward the coil in order to
prevent the pipe from uncoiling after cutting
4 Cut the shear cuts the pipe
5 hooking when cutting has been completed, the pipe guide moves to the first free reel ready for
coiling; the pipe is again hooked and coiling restarts
6 translation the strapping system translates laterally to the reel on which the coiling phase has just
been completed
7 paCking the strapping system performs 3 or 6 bindings according to the number
programmed by the operator
following each strapping operation, the reel rotates by 60° or 120° to the position for
performing the next
8 expulsion at the end of the packaging phase, the spattles move away from the coil and the
mobile portion of the reel opens.
An automatic expulsion system unloads the coil from the drum and slides it out of the
machine
9 Waiting the reel waits for the pipe to be hooked again
Should one of the two coils be stopped by the operator or a functioning anomaly, the winding will take place on one reel
only.
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Part II Machine installation and functioning
FB tR1860 l1/6
2.4 pipe-guide unit
oPeRatIon, adjustMents and contR l
The pipe guide distributes the coils during the coil winding and the shear cuts the pipe.
The translation of the pipe guide is carried out by means of an axis numerical control.
Main parts
A
C
B
ref. part desCription
a gauge A device that guides the pipe during coiling
b shear A device that cuts the pipe
C oscillating bar A device that adjust the coiling speed
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Part II Machine installation and functioning
FB tR1860 l1/6
2.4.1 mechanical adjustments
Install the suitable gaugeFit a gauge with a suitable size for the pipe to be coiled.
According to the agreements made with the customer
at the time of ordering, the coiling machine is supplied
with different types of gauges.
Each gauge supplied is printed with the diameter in milli-
metres of the matching pipe (A).
To replace it, unscrew the suitable screw as shown in
the picture.
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oPeRatIon, adjustMents and contR l
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Part II Machine installation and functioning
FB tR1860 l1/6
Inserting the pipeThe oscillating arm (a) is a device for regulating
machine coiling speed according to the approach
angle (b) (which will vary with pipe tension).
The pipe is to be introduced in a suitable ring (C)
placed at the base of the oscillating arm (a) and
must pass under the first sliding roll (d), which can
be adjusted by loosening the suitable screws indi-
cated in the figure.
Push the pipe until the meter counter wheel is
reached (d) then adjust the exiting roll (e), so as
to avoid up and down movements of the meter
counting wheel during coiling.
When small diameter pipes are being coiled, the
shoulder plate (F) must be adjusted so as to keep
the meter-counter wheel from jumping or bouncing
during coiling.
C a u t i o n - p r e c a u t i o n
oPeRatIon, adjustMents and contR l
F
- -
+ +
A
CE
D
B
the procedure of introduction of the pipe in the oscillating arm/pipe guide is extremely important for an optimal
functioning of the machine and thus it is to be carried out with the utmost attention by the qualified personnel
having particular technical specifications.
Tiro reggia Legatore2.4.2 pneumatic adjustments
Pipe guide arm back pressure
Adjust the guide pipe arm back pressure to offset the pipe lifting motion during the coiling
operation.
Espulsori Aspo 1 e 2 Scivoli Aspo 1 e 2 Spatola bassa Aspo 1
Friziona tuboDisables oscillating arm back pressureBy turning the two position selector switch clockwise, pressure can be discharged from
the oscillating arm back pressure circuit. By turning it anticlockwise, pressure can be
restored.
Braccio alto / basso Spatole alte Aspo 1 e 2 Pressione legatore
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Avanzamento Legatore
Spatola bassa Aspo 2
Contropressionebraccio oscillante
Disabilita contropression braccio oscillante
14
Tiro reggia Legatore Espulsori Aspo 1 e 2 o
Part II Machine installation and functioning
FB tR186 0 l1/6
High/low arm (Pipe guide back pressure)
Avanzamento LegatoreoPeRatIon, adjustMents and contR l
This device regulates the pressure that holds the pipe guide in the low position during
the coiling phase.
Friziona tubo ContropressionePipe braking device
braccio oscillanteControls the pressure applied by the cylinder which locks the pipe in position duringthe cutting stage and the sideways movement towards the other reel. Carefully set thepressure to the required value to firmly tighten the pipe without damaging it.
Scivoli Aspo 1 e 2 Spatola bassa Aspo 1 Spatola bassa Aspo 2Pipe pressing cylinderAdjusts the pressure applied by the pipe pressing cylinder during the coiling stage.Adjusts
the pressure in order to ensure the correct pressure on the pipe; however attention must
be paid so that the pipe is not damaged and can be smoothly and consistently coiled
patole alte Aspo 1 e 2 Pressione legatore Disabilita contropressionebraccio oscillante
2.4.3 adjustments of the pipe guide by the operator panel
Braccio alto / basso
Tiro reggia Legatore
Frena tubo
Friziona tubo
By means of the coiler management software, it is possible to modify several parameters which define the pipe guide device. A
detailed description is contained in the third part of this dossier (Manual for the software user) or by pressing HELP directly in line
on the display of the control panel.
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Part II Machine installation and functioning
FB tR1860 l1/6
2.5 reel unit
oPeRatIon, adjustMents and contR l
The reel is the heart of the machine. As it allows the user the make several manual adjustments and can easily be programmed
by means of a PLC, it ensures a fully and correctly coil the pipe.
All the mechanical and pneumatic adjustments required to ensure a correct use of the coiling machine are listed below. A
detailed description of how to program the software of the reel unit is available in Part III of the Software User Manual or on
the on line HELP, displayed directly on the screen of the control panel.
Main parts
G
ref. part
A Moving reel flap
B Fixed flange flap
C Pipe hooking
D Format Change
E Casings
F High paddles
G Low paddles
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D
C
E
F
A
B
desCription
They allow you to adjust the width of the
coil to be coiled They allow to contain
the coil during coiling
Adjustable device for the pipe hooking on the
reel
Device for automatic regulation of the petals
of the movig reel and of the shells
They allow you to select the internal diameter of the
coil to be coiled Device to prevent the coil unpicking
during the strapping phase
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Part II Machine installation and functioning
FB tR1860 l1/6
2.5.1 Functioning
oPeRatIon, adjustMents and contR l
After entering the correct settings for a specific production run, the pipe guide unit is moved to the first available reel ready to
latch the pipe.
The reel moving section is closed by latching the pipe and by starting the coiling stage.
The initial speed, i.e. the take-up speed, is higher than the normal operating speed and enables the operator to take up any
pipe that may have been left on the floor during the production run change or during the pipe guide sideway motion from one
reel to the next.
The fully taken up pipe is then pulled taut and, by means of the controls on the PLC, the oscillating arm unit is lifted, thus
slowing down the reel turning speed. The coiling operation is ended when the number of turns or metres set by the operator is reached.
At this point, the paddles will come closer and will lock the coil in position, stopping it from uncoiling during the strapping and
cutting stages. At the same time, the strapping machine will be moved closer and the strapping operations will be carried out.
At the end of this stage, the paddles will move away and the reel will be opened, whilst the ejectors will push the coiled pipe out
of the drum.
At the end of the full reel working cycle, the reel is automatically closed after the coil has been ejected and waits for a new
pipe to be latched. Should one of the two reels be manually stopped by an operator or stop because of a fault, the second reel
will carry on coiling the pipe.
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Part II Machine installation and functioning
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2.5.2 mechanical adjustments
Flange width (automatic adjustment)
oPeRatIon, adjustMents and contR l
The adjustment of the width of flanges (width of the coil) is
completely automatic and it is managed by the PLC.
By setting the desired value through the format change device,
the flange width is automatically adjusted to set the length of the
coil to be wound.
+
-
Drum diameter (automatic adjustment)
The adjustment of the diameter of the drum (internal diameter of
the coil) is completely automatic and it is managed by the PLC. By
setting the desired value through the format change device, the
internal drum diameter is automatically adjusted to set the
internal diameter of the coil to be wound.
-
+
C a u t i o n - p r e c a u t i o n
before adjusting the drum diameter, check that the pipe hooking device is in the limit stop position at the
farthest point from the center of the reel; that is, in a position not reachable by the spacer skirts of the drum
(see the section on pipe hooking)
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Part II Machine installation and functioning
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Pipe hooking (manual adjustment)
oPeRatIon, adjustMents and contR l
To achieve an optimal wounding action, it is essential to make sure that the pipe latches on
to the moving reel is as accurately and as firmly as possible, in order to avoid malfunctions
during production. The picture shows an example of a pipe perfectly latched onto the reel.
To achieve this, pipe latcher (a) plate must be replaced at every
production change according to the diameter of the pipe to be B
produced, by removing the screws which fasten it to moving
flap (b). Further changes to the latching position are achieved
by moving the device along axis Y (vertically) on one of the
differently spaced out rear holes (C). Essentially, these holes
serve the purpose of adjusting the spring pulling action in order
to stop undesired movements of the pipe after latching onto the A
reel.
C
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Part II Machine installation and functioning
FB tR1860 l1/6
High paddle position (manual adjustment)Adjust the transversal position of the paddle arm by
referring to the position that the coil queue end will
take.
Slacken the paddles of both reel.
Low paddle position (manual adjustment)Adjust the transversal position of the paddle arm by
referring to the position that the coil queue end will
take.
Slacken the paddle with the locking screws
and slide it along the support pin. Slacken the
paddles of both reel.
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oPeRatIon, adjustMents and contR l
CC
BB
AA
A. Screw for the transversal adjustmentB. Reel 2 high paddleC. Reel 1 high paddle
BB
CC
AA
A. Screw for the transversal adjustmentB. Reel 2 low paddleC. Reel 1 low paddle
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Part II Machine installation and functioning
FB tR1860 l1/6iro reggia Legatore Avanzamento Legatore
2.5.3 pneumatic adjustments
Reel 1 and 2 High paddles
oPeRatIon, adjustMents and contR lEspulsori Aspo 1 e 2 Scivoli Aspo 1 e 2
It adjusts the pressure of the high paddles on the coil of both reels
Operate on the pressure adjuster according to the production being carried out (length,
diameter, number of turns, layers of pipe…).
Make sure that the paddle is not overtightened as this would cause the pipe to be
unevenly wound (minimum pressure about 1 bar).
Friziona tubo Contropressione Braccio alto / bassoReel 1 Low paddle braccio oscillanteAdjusts the pressure of the low paddle onto the reel 1 coil.Operate on the pressure adjuster according to the production being carried out (length,
diameter, number of turns, layers of pipe…).
Make sure that the paddle is not overtightened as this would cause the pipe to be une-
venly wound (minimum pressure about 1 bar).
anzamento Legatore Espulsori Aspo 1 e 2 Scivoli Aspo 1 e 2
Reel 2 High paddle
It adjusts the pressure of the high paddle on the coil of reel 2Operate on the pressure adjuster according to the production being carried out (length,
diameter, number of turns, layers of pipe…).
Make sure that the paddle is not overtightened as this would cause the pipe to be une-
venly wound (minimum pressure about 1 bar)
Espulsori Aspo 1 e 2 Scivoli Aspo 1 e 2 Spatola bassa Aspo 1Contropressione Braccio alto / basso Spatole alte Aspo 1 e 2braccio oscillante
Braccio alto / basso Spatole alte Aspo 1 e 2 Pressione legatore
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Spatole alte Aspo 1 e 2
Spatola bassa Aspo 1
Spatola bassa Aspo 2 Pressione legatore
Disabilita contropression braccio oscillante
21
Friziona tucbo isrdoccio alto / bassoSuser)ole alte Aspo 1 e 2Ctiontropressionebraccio oscillante
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Part II Machine installation and functioning
FB tR1860 l1/6
Reel 1 and Reel 2 ejectors
oPeRatIon, adjustMents and contR l
Regulates the pressure applied by the ejectors on the coils of both reels
Set the pressure regulator according to current production taking into consideration
factors such as dimensions and weight. Make sure the pipe is not ejected too quickly or to
suddenly.
Tiro reggia Legatore Avanzamento Legatore
Friziona tubo ContropressioneReel 1 and Reel 2 Slide braccio oscillanteSets up reel 1 and 2 slide ascent
Set the pressure regulator according to current production, taking into consideration, for
example, the weight of the coil.
iro reggia Legatore Avanzamento Legatore Espulsori Aspo 1 e 2
2.5.4 adjustments of the reel from the operator panel
Espulsori Aspo 1 e 2
Braccio alto / basso
Scivoli Aspo 1 e 2
By means of the coiler management software, it is possible to modify several parameters which define the reel devi-
e. A detailed descrip on is contained in the third part of th ssier (Manual for the software or by pressing HELP
directly in line on the display of the control panel.
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Fase desCdezione
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Part II Machine installation and functioning
FB tR1860 l1/6oPeRatIon, adjustMents and contR l
2.6 strapping machine and strap unwinding machine
Each strapping unit is enabled for performing strapping on the coils of either reel.
Main parts
A
E B
C
FD
rif. part sCription
a strap unwinding machine A device that contains and unrolls the strap during coiling
b strap pressing rolls A device that pushes the strap towards the reel
C sealing spout A device that glues the strap at high temperature
d strapping machine grippers Strap gripper, sealer and cutter
e strap puller device
F strap tightening
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A device that gives tension to the strap during the recovery phaseduring the sealing phase
A device that supplies a certain and regular quantity of strap to the strapping machine
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Part II Machine installation and functioning
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2.6.1 Functioning
Its cycle develops as follows:
DROP
CRIMPING
RECOVERY
TENSIONING
CUT
SEALING.
oPeRatIon, adjustMents and contR l
The drop is carried out by means of four rollers which, by rotating and pressing the strap, push it forward, by suitably guiding it
by means of mechanical guides (cable run) (E), in order to wind the coil of wire. At this point slotted pincers (A) moves
forward to block the strap and the rollers recover the coil of wire in excess.
Then, it is put under tension by the couple adjusting of the launch motor.
Pincers (C) pushed forward to block the ends of the free strap, while the sealing spout sealing blade is introduced between
the two strap endings divided by the plate (D), by heating them. As the sealing blade removes, the plate goes downwards,
pincers (B) moves forward, cuts the strap and press the two endings by sealing them.
A
B
C
D
E
E
C a u t i o n - p r e c a u t i o n
improper adjustments could cause the strapping system malfunctioning!
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AL LEGATORE
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Part II Machine installation and functioning
FB tR1860 l1/6
2.6.2 strap introduction or change
oPeRatIon, adjustMents and contR l
1 Make sure that the machine has come to a full stop and the air supply has been disabled.
2 Unscrew the strap unwinding disc (A) by rotating it clockwise once and removing it (see the picture). 3
Place the strap coil on the coil mounting.
4 Refit the disc in the strap unwinder and lock rotating it anclockwise
5 Insert the strap end inside the strap tie rod, as shown by the arrows in the picture.
For a better graphical representation, the strap is blue in the upper side and yellow in the lower one.
OUT
TO THE
S TRAPPInG MACHInE
A
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Part II Machine installation and functioning
FB tR1860 l1/6oPeRatIon, adjustMents and contR l
6 Remove the strap from the last roll upwards and introduce it in the pincers by following the natural strap curve, as shown
in figure (A).
7 Disable the roll pressure by lifting the lever (B), and push the strap until the strap guide channels are reached. 8
Lower again the lever. 9 Restore the air and power supply and cut the strap from the keyboard in order to remove any faults.
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Strap tensioning device pressure
By rotating leftward the pneumatic switch, it is possible to cut the pressure to the
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Part II Machine installation and functioning
FB tR1860 l1/6
2.6.3 pneumatic adjustments
Strapping machine Head feeding
oPeRatIon, adjustMents and contR l
Adjust the pressure which is necessary to the strapping machine to press the coil
during the final phase of the strapping operation. A high pressure causes a crush of
the pipe. By operating on the pressure regulator, adjust the manometer according to the
type of pipe being winding.
Tiro reggia LegatoreStrapping machine Strap puller DeviceAdjust the pressure which is necessary for the cylinder to tension the strap.
A high pressure can cause an obstruction of the pipe or the break of the strap. Adjust the
pressure according to the characteristics of the pipe to wind.
anzamento Legatore Espulsori Aspo 1 e 2 Scivoli Aspo 1 e 2
Strapping machine pressure
Friziona tubopneumatic circuit of the strapping machine.
Contropressione Braccio alto / basso Spatole alte Aspo 1 e 2braccio oscill ante
It adjusts the pressure of the strap tensioning cylinder so as to have the strap intro-duced in the roll and so that it remains under the right tension. Too much pressure
can break the strap.
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Avanzamento Legatore
Spatola bassa Aspo 1
Tiro reggia Legatore
Contropressione braccio oscillante
Pressione legatore
Friziona tubo
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Part II Machine installation and functioning
FB tR1860 l1/6oPeRatIon, adjustMents and contR l
2.6.4 adjustments of the strapping machine by operator panel
By means of the coiler software, it is possible to modify several parameters which control the functioning of the
strapping machine.
The third part of this dossier will explain in details the subject (manual for the software user).
2.6.5 adjustments by operating on the electrical board
Sealing blade temperature adjustment
According to the type of strap used, it can be necessary to vary the temperature of the sealing spout. The thermo-adjuster is
placed on the front panel of the electrical board.
SET POInT RAPID PREPARATIOn
This procedure allows you to fast prepare the active set-point. For further information about the thermo-adjuster, please refer to
the Manual Rotfil attached to the documentation of the machine.
Press the button p and the display will visualize “SP n” (n is the Set Point number which is active in that moment) alter-
nated to the selected value
Operate on buttons UP and DOWN to increase/decrease the value
After selecting the required values, press button p in order to leave the preparation of the Set Points.
OUT2 OUT1
U P
i n f o r m a t i o n
attention: the temperature of the resistance is already selected at an optimal value.
an improper modification can cause the strapping machine malfunctioning.
Further specifications of the digital thermoregulator are contained in the attached manual.
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Part II Machine installation and functioning
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2.6.6 sealing blade replacement
Sealing blade positioning1 If necessary, adjust the position of the sealing
blade by means of the shoulder screw placed in
the back part of the sealing spout (a).
2 Operate on the screw so that the sealing blade,
by lowering, finds its position between the two
strap endings (b).
3 If the above is not enough, also operate on the
shoulder screw of the sealing spout (C).
Check in particular that the sealing blade is introdu-
ced in a perpendicular way in relation to the base of
the small plate within the 2 strap stocks.
Sealing blade replacementIIn case of break, the heating element (cartridge) can
be replaced as follows.
1 Remove the sealing spout protection by operating
on the suitable screws (a).
2 Unscrew by means of a special key the screw
indicated in figure (b).
3 Remove the heating element (C) and replace it
with one having the same technical characteri-
stics, paying attention to reconnect correctly the
electrical wires as shown in the electrical sche-
me.
d a n g e r - a t t e n t i o n
oPeRatIon, adjustMents and contR l
danger oF burn, deviCes undergoing high temperature. avoid the ContaCt With the hot
parts on the head oF the strapping maChine. the sealing spout oF the strap made oF
polypropylene is heated at temperatures exCeeding 300 °C
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Part II Machine installation and functioning
FB tR1860 l1/6
2.7 Command panel
oPeRatIon, adjustMents and contR l
The command panel is essentially composed of two parts:
A the Operator’s terminal is the real interface between the machine and the user
B the additional buttons that permit the operator to start or stop the machine.
2.7.1 operator’s terminal
The TOUCH SCREEN operator panel displays machine operation status reports, instantaneous process values, and any
anomalies in machine operation. The operator can also create “Recipes” consisting of the sets of parameters needed to
compile a database relative to the different types of production.
Thanks to the graphic interface, use of the various screens is simple and intuitive. The operator need only touch the screen to
select menu items or enter data.
For detailed information on how numerical control operates, refer to the Software User’s Manual, Part 3 of the Use and
Maintenance Manual.
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Part II Machine installation and functioning
FB tR1860 l1/6
2.7.2 additional buttons
oPeRatIon, adjustMents and contR l
In the following page the description of the buttons not included in the Operator panel.
a) motor reaCtivation button
It allows you to reset the motors every time that the
safety device is activated by an emergency stop or the
start up of the coiler. Press the button after eliminating
the cause.
b) AIR RESET BUTTON
It allows you to reset the power of the circuits which
are not managed by the numerical control and of the
air pressure on the whole pneumatic circuit each time
the safety device is activated by an emergency stop,
by the opening of one of the protection bars or by
the stop button. By pressing the button for at least 5
seconds, an acoustic device will signal the restart of
the machine. Should the operator be inside, immedia-
tely operate on one of the emergency buttons placed
at the sides of the columns or on the Operator’s ter-
minal.
C) ALARM RESET BUTTON
It allows you to zero the alarms on the display of the
Operator panel after they have been removed.
d) MACHINE STOP BUTTON
It has the same function of the opening of the protec-
tion bars, causing the exclusion of the air pressure in
the whole pneumatic circuit, leaving activated the low
tension and a part of the circuit of power so that the
activations of the motors do not loose the values.
To restart the coiler, press only the button (B) AIR
RESET.
e) EMERGENCY STOP BUTTON
SIMATIC OP 17
M
F1 F2 F3 F4 F5 F6 F7 F8
A1 A1 A1 A2 CF1 L1 L1 L1 HELP
TOP STOP
SHIFT
A2 A2 A1 A2 CF2 L1 z
x y
ESC
7 8 9 0D E F ACK
4 5 6A B C INS
1 2 3 + / - SHIFT DEL HELP ENTER
F
A
BC
D
E
It allows you to immediately stop the coiling by cutting the power, low power and pressure to the pneumatic circuit. To restart the
coiler, reset the button (mushroom), press (B) MOTOR REACTIVATION, (C) AIR RESET and reset the alarms from the display
(ACK).
F) SIREN ACTIVATION BUTTON EVERY TIME AN ALARM IS GIVEN
It allows you to select the siren so that in the presence of alarms, further to the luminous signalising, you also have an acoustic
signalising. (Position the selector on 1 to enable the acoustic signalisation).
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Part II Machine installation and functioning
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2.7.3 damper battery replacement
oPeRatIon, adjustMents and contR l
When the coiler is not under tension, the management software is stored by the PLC by means of a lithium battery SIEMENS
6ES5 980-0MA11. When the battery is almost exhausted, the machine stops and on the operator terminal P.L.C. MEMORY
DAMPER BATTERY EXHAUSTED is visualized.
It is possible to disable the alarm and go on with production by selecting YES when BATTERY ALARM DISABLING on the
service page of the menu “Various parameters” is visualized.
d a n g e r - a t t e n t i o n
should the battery not be replaCed in a short time (2/3 days) this Can Cause the lost oF
the management soFtWare
d a n g e r - a t t e n t i o n
it is neCessary that only the qualiFied personnel is Charged oF this operation, beCause
non insulated parts under high tension are still aCCessible
In order to replace the battery, proceed as follows:
1. Open the panel indicated in the figure when the PLC is under tension
2. Open the gate of the battery case placed on the PLC
3. Replace the battery
4. Close the case gate
5. Check that led 3 (PLC Scheme) is off (if not so, check the correct introduction
of the battery or replace it again)
6. Close the control panel
7. If enabled, disable the function BATTERY ALARM DISABLING
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Control panel scheme
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Part II Machine installation and functioning
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3. maChine starting up and stop
MachIne staRtIng uP and st P
During the use of the machine, different conditions of starting up and stop can take place. By taking into consideration the
articulation of the sequence actions which is necessary to carry out, each of these is developed by means of a flow scheme.
Here follow the main phases.
3.1 machine starting up
It includes the phases of starting up and the activation of the work cycle.
Insert the pipe in the coilingmachine (see par. 2.4.1).
Turn the main power switchto ON (I) and check that the power indicator lights are supplied power
Start the machine by pressing the motor reset button. The button
is enabled approximately 10 sec.after turning on the main switch
Press the aCk button from the operator terminal to reset the alarms
displayed on the screen
Then press run button k9, then k10 to carry out an ejection operation
without strappings on reel 2
Check the emergency devices byresetting the devices on
Start the machine by keeping thebutton air reset
pressed for at least 5 sec. signalledby the acoustic signal
Press the k16button from the operator terminal to
synchronise the axes
z
x y
After the pipe has been ejected, the coiling machine will automatically stop. At this point, insert the pipe
inside the coiling machine(see par. 2.4.1)
Check that the key forthe disabling of the
protection cage is on0 (enabled protections)
After about 5 seconds from resetting air supply, press the
alarm reset button
When k16 indicator light is switched off (after synchronisation has taken place) press k1 Run button, thenpress k2 to carry out an ejection
operation without strappings on reel 1
after
Press k1 and k9 to start the coiling operation. The machine will go into auto mode. The first reel to comple-te the coil ejection cycle will start to wind the pipe. At this point, manual intervention is only required if faults
occurA2
after
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Manual Matr. 740 - 10.05 A2 A2
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Part II Machine installation and functioning
FB tR1860 l1/6MachIne staRtIng uP and st P
3.2 machine stop caused by an emergency device (mushroom shaped emergency button)
Activate an emergency Identify and eliminate the Reset the emergencydevice and leave it causes which have caused device
enabled. Wait until all the the emergency stop. (If it is the case of themoving parts are stopped In particular, check mushroom, turn the red
that nobody is inside button)the machine
Start the machine by pres- Start the machine by kee- After about 5 seconds fromsing the motor reset ping the button air reset resetting air supply, pressbutton. The button is ena- pressed for at least 5 sec. the alarm reset buttonbled approximately 10 sec. signalled by the acousticafter turning on the main signal
switch
Press the aCk button from Press k1 and k9 to restartthe operator terminal to the coiling operation from
reset the alarms displayed the point where it wason the screen stopped
A2
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Part II Machine installation and functioning
FB tR1860 l1/6MachIne staRtIng uP and st P
3.3 machine stop caused by the opening of the safety barriers or by the stop button
Identify and eliminate thecauses which have caused
the stop.
After about 5 seconds fromresetting air supply, pressthe alarm reset button
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Close the doors if theyare open and/or check the
presence of any foreignsubstance in front of the
photocells
Press the aCk button from the operator terminal to
reset the alarms displayedon the screen
Start the machine by kee-ping the button air resetpressed for at least 5 sec.signalled by the acoustic
signal
Press k1 and k9 to restartthe coiling operation from
the point where it wasstopped
A2
35
Part II Machine installation and functioning
FB tR1860 l1/6
3.4 switching the machine off
Press k1 and k9 to stopthe winding operation in
progress
A2
+
Remove the pipe from themachine if still present.
Turn the main power switchto oFF (0)
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Carry out the coil ejectionstage with or without strap-ping according to the num-
ber of meters wound
or
A2
or
MachIne staRtIng uP and st P
Press the emergencybutton located on the
operator’s control panel
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FB tR1860 l1/6 seRVI
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4. serviCe
4.1 ordinary service general indications
The ordinary service interventions can be carried out by the authorized operator. Even if these interventions are not as com-
plicated as those of extraordinary service, it is necessary to prepare suitable safety conditions for people in compliance with
the law in force relating to the safety and health in the working places.
C a u t i o n - p r e c a u t i o n
1. before any service operation, check that the power switch is oFF and that the pneumatic supply is disabled.
2. Wait at least one minute before approaching the electronic machines, in order to allow the condensers
discharge the residual energy.
3. during handling the lubricants, do not smoke, eat and drink. Follow the instructions in force relating to the
handling of the mineral oils and greases. in order to prevent from irritations or allergies, always wear glasses
or anti-spray mask, and anti-oil gloves.
4. For those who are particularly sensible to lubricants, it is possible an allergic reaction. it is suggested to
avoid any contact with the skin. the contact with eyes can cause irritations.
Weekly
Clean the head of the strapping system with gas oil and blow with compressed air, by carefully eliminating all the strap
polypropylene residuals.
Clean the mechanical parts with compressed air.
Protect the metal parts exposed to corrosion agents with non-aggressive light lubricants.
Clean the keyboard of the local terminal with suitable non-aggressive products for plastics and synthetic gums.
Check the efficiency of the safety switches mounted on the electrical inter-block circuit of the protection cage.
Check the efficiency and clean the strap cable run guide mounted on the “fixed reel” and “moving reel” groups.
Check that the inductive sensors mounted on the “reed” pneumatic cylinders and the other inductive sensors (analogical
and digital) are well fixed in the correct position.
Check the efficiency of the limit switch hydraulic dampers of the different devices.
Check the general efficiency of the machine:
• Fixing screw tightening
• Machine kinematical stroke free movement
• Machine kinematical movement guide clearances
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Part II Machine installation and functioning
FB tR1860 l1/6a
Periodically
Control and eventual blow water down on the compressed air inlet group
filter (a).
Control and eventual cleaning of the ventilation air filters
placed on the electrical panel:
1. Remove the case (a).
2. Remove the filter (b) and clean it with an air jet. a
Greasing of the moving slides of the group: reel, strapping
machine and pipe guide (approximately every 6 months).
Check the tightening of the air pipe and electro-valve gaskets.
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b
a
a
b
a
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4.2 materials supplied
In the following table are reported the articles supplied with the coiler.
Code desCription pieCes
Fb20040008 SENSOR IN.12MM 24VDC SAIEA1PMU/3AP 1
Fb20130020 MASCHIO 4POLES MALE COATING CODE 113734 1
Fb20130022 PLUG CONTACT 1,5MM CODE 116527 4
Fb20130023 YELLOW GASKETS CODE 116531 4
Fb20200026 RESIST.UTC D12.7 L38.1 W120 V12 DRI 1
Fb40070018 LIMIT SWITCH SME 8-S LED 24 1
Fb10300097 CONTAINING SPARE PARTS TR1860 1
4.3 spare parts
i n f o r m a t i o n
in order to keep the machine at its utmost efficiency, respect the service interventions programmed
by the manufacturer.
before carrying out any replacement intervention, check that the machine is stopped and that all the safety
devices are enabled.
if it is necessary to replace used components, only use original spare parts.
to order the spare parts, identify in the list attached to the manual (part v: list of the electrical spare parts and
list of the pneumatic spare parts) the code of the part to replace and then contact the manufacturer F.b. balzanelli
avvolgitori spa.
indicate the code of the article F.b. and the relating description.
F.b. balzanelli avvolgitori spa. declines any responsibility for damages to people or components caused by
repairs carried out without the authorization of the manufacturer or by the use of non original spare parts.
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4.4 Consumption materials
Here follows the list of those materials undergoing the utmost consumption with the relating average life.
These data are approximate because they are very variable.
osCillating arm group Meter-counting wheel “OR” gums (about 1 year)
reel unit Check the wear condition of the tiles
strapping maChine Strap drop motor belt (about 5 years)
Sealing spout resistor (about 1 year)
pipe guide/shear unit Check the wear condition of the pipe cut shear blade
Check the wear condition of the different types of gauge
Check the wear condition of the pipe guide wheels
eleCtriCal Control panel PLC back-up battery (about 1 year)
operator panel OP17 keyboard back-up battery (about 2 years)
maChine board Limit switch hydraulic dampers (about 5 years)
Inductive sensors (about 5 years)
4.5 machine dismantling
This operation must be carried out by the qualified personnel who operates by respecting the laws in force relating to the
environment and safety in the working places.
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FB TR1860 L1/6 Part IIISoFTwaRe USeR ManUaL
Scope and LimitationS of thiS manuaL ..........................................................................42
cautionS ........................................................................................................................ .42
1. controL paneL .......................................................................................................431.1 Operator terminal . . . 431.2 Password . . . 441.3 Password hierarchy . . . 44
2. operator terminaL generaL uSe .............................................................................452.1 Display . . . 452.2 System keys . . . 462.3 Numeric keyboard 482.4 Function keys keyboard . . . 49
2.4.1 Function keys . . . ...492.4.2 Action keys . . . ..50
3. uSing the SoftWare ................................................................................................553.1 Information pages . . . 553.2 Parameter entering 573.3 Reserved pages . . . 613.4 Recipe management . . . 63
3.4.1 Creating a typical recipe . . . .663.4.2 Changing the title of a typical recipe . . . .67
3.5 OP17 Main Page (Reserved page). . . 68
4. aLarmS ................................................................................................................ .694.1 Overview . . . 694.2 Alarm messages index . . . 69
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FB TR1860 L1/6 SoFTwaRe USeR ManUaL
Scope and LimitationS of thiS manuaL
This manual describes the typical operations and procedures required to produce programs that can be executed with the
software. The user is recommended to read the User Manual and enclosures supplied with the machine before reading this
Manual in order to get familiar with the machine and use it safely.
cautionS
Before using the machine, read the safety information contained in the first section of the machine User Manual.
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Part III Software User Manual
FB TR1860 L1/6 conTRoL PaneL
1. controL paneL
The control panel consists of two main parts:
• The operator terminaL is the true interface between machine and user
• The additionaLS KeYS allow the operator to reset the air/power supply or to carry out a machine emergency stop
operation (See Part II, Chapter 4).
1.1 operator terminal
SIMATIC OP 17
LIQUID CRYSTAL DISPLAY
F1 F2 F3 F7 F8FUNCTIONKEYS
FUNCTIONKEYSKEYBOARD
NUMERICKEYBOARD
ACTIONKEYS
7 8D E
4 5A B
1 2
A1 A1 A1 A2 CF1
A2 A2 A1 A2 CF2
9 0F
6C
3 + / -
L1 L1 L1STOP
L1 z
x y
INSSHIFT HELP
DEL
SYSTEM KEYS
HELP INDICATOR
LEDS
SHIFT
ESC
ACK
ENTER
SiemenS op17 operator terminal consists of:
display
System keys
function keys keyboard
numeric keyboard
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LCD display with LED backlighting
6 keys used to recall general standard functions
3 LED indicator lights
4 cursor keys used to navigate inside the program pages
24 keys (from f1 to f8 and from K1 to K16) used to recall the machine functions
Used to enter numeric values
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1.2 password
To make sure the operator terminal is not misused, different password levels have been set in the various maintenance
pages. These levels are hierarchically set in ascending order from 0 to 9. When assigned a password, the operator has the
right to carry out the functions associated with a specific password level.Entering a higher level password allows the operator to
automatically access the lower level passwords.These passwords, set up during the design stage, cannot be changed by the
final user and are directly notified by the manufacturer. Higher password levels can only be used by F.B. Balzanelli Avvolgitori
Spa technical staff.
1.3 password hierarchy
A general description of the different password levels is provided below
LEVEL 0 This is the lowest hierarchy level, which allows the operator to carry out only very basic functions only marginally affecting the process. Generally speaking, these functions do not allow the operator to enter values (read only function). To recall the functions requiring password 0, no password is required. If a function requiring a level higher than 0 is recalled, the display will prompt the operator to enter the associated password.
LEVEL 1 - 8 As function importance becomes greater, the functions are associated with levels ranging from 1 to 8.
LEVEL 9 Functions requiring password level 9 can only be carried out by a Superuser, who has the right to access all operator terminal functions.
The Superuser only has the duty of managing all passwords. For detailed information, please refer to the Siemens op17
operator terminal manual (enclosure B-1).
The terminal can be set up in such a way as to allow the 2 reels to be managed independently. By doing so, pipes can be
coiled on two different types of production (such as on reel 1, by coiling 25 meters of pipe and on reel 2 by coiling 50 meters). For
obvious technical reasons (such as pipe diameter), some parameters are the same for both reels.
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2. operator terminaL generaL uSe
2.1 display
The LCD with LED backlighting can be viewed in 2 resolutions:
4 lines of 20 characters each (character height: 11 mm)
8 lines of 40 characters each (character height: 6 mm)
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2.2 System keys
c a u t i o n - p r e c a u t i o n
Pressing multiple keys simultaneously can cause errors
KeYto functoion deScriZiond
SWitch
deLete
inSert
+
info
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oPeRaToR TeRMInaL geneRaL U e
SIMATIC OP 17
HELP INDICATOR
LEDS
SHIFT
ESC
ACK
INSSHIFT DEL HELP ENTER
SYSTEM KEYS
eScription
This key disables the second function of “dual” function keys; for example, it switches keys from 1 to 6 to characters a to f of the numeric keyboard. When the Shift key is pressed, the Shift LED indi-cator light will be illuminated.
When alphanumeric characters are entered, the character pointed by the cursor is deleted.
A space in the current cursor position is inserted.
If the heLp LED is on, a description of the para-meters or a help associated with the item currently displayed can be recalled.
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KeYto functoion
enter
aLarm reSet
eScape
moVing the curSor
oPeRaToR TeRMInaL geneRaL U e
deScriptoion
Used to confirm entered data or to stop entering
data.
Used to remove an alarm displayed on screen. If an
alarm is displayed, the matching LED will be
illuminated.
The eSc key is used to stop viewing a page, an
indicator or to stop entering field data and to return to
the previous status.
According to the operation being carried out, the
cursor is moved by one character, a field, an entry or
a display to the left, right, up or down.
+ ScroLLing a SYmBoL LiSt and acceSSing the eXtended character Set
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2.3 numeric keyboard
7 8 9 0NUMERIC D E F
KEYBOARD 4 5 6A B C
1 2 3 + / -
KeY
a
+
a
+
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SIMATIC OP 17
deScription
numeric VaLueSEntering numeric characters from 0 to 9
aLphanumeric characterSAllows to enter alphanumeric charactersfrom a to f
changing SignAllows to change the sign from + to - andvice versa
adJuSting the contraStAllows the display contrast to be adjusted
inSerting a decimaL pointAllows the decimal point or comma to beinserted
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2.4 function keys keyboard
oPeRaToR TeRMInaL geneRaL U e
The function keys keyboard may be split into two separate areas:
SIMATIC OP 17
F1FUNCTIONKEYS
FUNCTION ACTIONKEYS KEYSKEYBOARD
F2 F3 F7 F8
A1 A1 A1 A2 CF1 L1 L1 L1STOP
A2 A2 A1 A2 CF2 L1 z
x y
the function keys, identified by the letter “f” associated with entering and displaying the parameters, have a light green
background
the direct action keys, identified by the letter “K”, have a blue background.
2.4.1 function keys
f function KeYS
f1 Allows the coiling machine INFO pages to be accessed f2 Allows the parameter entering mode to be accessed f3 Allows the reserved pages parameter entering mode to be accessed f4 No associated function f5 No associated function f6 No associated function f7 Allows the DATA SET parameter entering mode to be accessed f8 Allows the OP17 MAING PAGE parameter entering mode to be accessed
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K1 K2 K5 K7 K8
K9 K10 K12 KK14 KK15 KK16
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2.4.2 action keys
oPeRaToR TeRMInaL geneRaL U e
The coiling machine is a fully automatic machine but, if needs be (such as when alarm messages are displayed) the operator can
manually operate the machine through action keys K.
Thanks to the icon system used, these keys are user friendly. A short description of action keys is shown below.
The action keys from K1 to K16 have a RED/GREEN dual colour LED which, according to the function selected, may be
enabled or disabled, and have a specific meaning, described in the following pages
Key ID
Function group code associated
Red/green indicator light LED K1 with the controlA1
Control key symbol
K1 K2 K33 K4 K5 K6 K7 K8
A1 A1 A1 A2 CF1 L1 L1 L1STOP
K9 K10 K11 K12 KK1 3 4 5 6
A2 A2 A1 A2 CF2 L1 z
x y
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K action KeYS
K1 reel 1 run/stop
oPeRaToR TeRMInaL geneRaL U e
This key allows the reel to be started. When the reel is moving, the LED will be green. If the key is pressed
during the coiling stage, the reel will be stopped and the LED will turn red. If the reel is disabled, the LED
will turn red and will be flashing.
GREEN LED: Reel 1 moving RED LED: Reel 1 stopped
FLASHING RED LED: indicates that reel 1 is disabled and that reel 2 can now start winding. This condition
occurs when the run / stop key is pressed for at least 5 seconds. If the key is pressed again, reel 1 will
start running again.
K2 eject without strapping on reel 1
This key allows the coil to be ejected without strappings on reel 1. This control key has no effect if reel 1 is
strapping.
GREEN LED: Booking of ejection without strappings enabled
K3 ejection with strappings on reel 1 and reel 2
This key is used to immediately eject the coil with strappings on both reels. The control key has no effect if
one of the 2 reels is carrying out the strapping operation.
GREEN LED: Booking of ejection with strappings enabled
K4 cf1 format change
CF1 Press this key to carry out the format change operation. At the end of the coil strapping, the reel is closed,
it will search the position set up in the reserved parameters page and will be stopped. Before starting the
format change cycle, the pipe latching monitoring alarm will be displayed. Make sure the latch is loosened
and RESET THE ALARM.
GREEN LED: format change booked.
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K5 enable / disable strapping device
oPeRaToR TeRMInaL geneRaL U e
L1 This key enables or disables the strapping device operation.
K6 Strapping device strap throwing
This key is used to throw the strapping device strap (this operation is required when the “failed throw”
message is displayed on the screen).
FLASHING RED LED: Allows the operator to manually throw the strap. This function is essential when the
machine cannot carry out the strapping operation automatically.
K7 Strapping device strap cutting
This key allows the strapping device strap cutting operation to be carried out (this operation is useful
during a strapping coil change or when the strap is found to be defective).
GREEN LED: Strapping device strap cutting in progress.
K8 pipe braking device
This is required when, if a pipe is inserted when the machine has stopped, the pipe brake must be manually
opened. After inserting a pipe, the key must be pressed again to enable the automatic mode
GREEN LED: Indicates that the braking FLASHING RED LED: Indicates that the
system is enabled and is automatically con- braking system is automatically disabled
trolled by the PLC and the operator can manually insert the
pipe
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K9 reel 2 run/stop
oPeRaToR TeRMInaL geneRaL U e
A2 This key allows the reel to be started. When the reel is moving, the LED will be green. If the key is pres-
sed during the coiling stage, the reel will be stopped and the LED will turn red. If the reel is disabled, the
LED will turn red and will be flashing.
GREEN LED: Reel 2 moving RED LED: Reel 2 stopped
FLASHING RED LED: indicates that reel 2 is disabled and that reel 1 can now start winding. This condition
occurs when the run / stop key is pressed for at least 5 seconds. If the key is pressed again, reel 2 will
start running again.
K10 eject without strapping on reel 2
A2 This key allows the coil to be ejected without strappings on reel 1. This control key has no effect if reel 2is strapping.
GREEN LED: Booking of ejection without strappings enabled
K11 manual take-up speed
A1 A2 When this button is pressed, the coiling machine starts turning at a “manual take-up” speed. This speed,
normally higher than the normal coiling speed, is used to take up any pipe left on the ground during a pro-
duction change. After taking up the pipe and releasing the key, the normal coiling speed is restored.
GREEN LED: Take-up speed enabled (this control key must be held down).
K12 cf2 format change
CF2 Press this key to carry out the format change operation. At the end of the coil strap-
ping, the reel is closed, it will search the position set up in the reserved parameters page and will
be stopped. Before starting the format change cycle, the pipe latching monitoring alarm
will be displayed. Make sure the latch is loosened and RESET THE ALARM.
GREEN LED: format change booked.
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K13 release strap unwinder
oPeRaToR TeRMInaL geneRaL U e
L1 When this button is pressed, the strap unwinder is locked, thus allowing the strap to turn freely.
GREEN LED: Indicates that the strap unwin- FLASHING RED LED: Indicates that theder is locked and automatically controlled by strap unwinder lock has been manuallythe PLC. disabled.
K14 no associated function
K15 no associated function
K16 Synchronise axes
z
x y
Each time the machine is started, axes must be manually reset. When the axes are not reset and therefore
the LED is not flashing; when pressed, this control key allows the operator to position the pipe guide first in
line with reel 1 internal flange; when pressed again, the pipe guide will be moved to reel 2 internal flange.
FLASHING RED LED: Indicates that a coiling machine manual axes reset has been requested.
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3. uSing the SoftWare
3.1 information pages
The parameters entered in this page are read only parameters and therefore do not require any password.
To navigate inside each sub page relating to the function key (f1) press the SeLection arroW keys:
Screen 1/5generaL info
TR1860L1/6 - 740 (1) 12:02:25 (2)
12:09:05 (3)
coils produced (4)
metres of pipe coiled (5)
A1 number of revolutions (6)
A2 number of revolutions (7)
generaL info
READING PARAMETERS (1)
number of active recipe (2)
reel 1 flange width (3)
reel 2 flange width (4)
quality control (5)
layer number (6)
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1. Coiling machine type and serial number
2. Time: hours, minutes and seconds
3. Date: day, month and year
4. Number of pipes coiled
5. Current measurement of metres of pipe coiled
6. Current measurement of revolutions carried out by reel 1
7. Current measurement of revolutions carried out by reel 2
Screen 2/5
1. Page title
2. Viewing currently active recipe
3. Viewing flange width associated with reel 1
4. Viewing flange width associated with reel 2
5. Coil part counter for quality control operation; indicates the number of coils
produced after the last quality control operation carried out (editable entry)
6. Number of layers coiled
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PROGRAM STEPS (1)
reel 1 steps cycle (2)
reel 2 steps cycle (3)
pipe guide steps cycle (4)
strapping machine steps cycle (5)
aXiS aLarm
READING PARAMETERS (1)
reel 1 axis alarm (2)
reel 2 axis alarm (3)
pipe guide axis alarm (4)
pipe guide arm axis alarm (5)
aXiS VaLue
READING PARAMETERS (1)
reel 1 axis degrees value (2)
reel 2 axis degrees value (3)
pipe guide axis degrees value (4)
pipe guide arm axis degrees value (5)
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USIng THe SoFTwa Re
Screen 3/5
1. Page title
2. Visualization of the step of the program in relative course of execution to reel 1
3. Visualization of the step of the program in relative course of execution to reel 2
4. Visualization of the step of the program in relative course of execution to pipe
guide
5. Visualization of the step of the program in relative course of execution to strap-
ping machine
Screen 4/5
1. Page title
2. Displays the alarm code relating to reel 1 numeric control (*).
3. Displays the alarm code relating to reel 2 numeric control (*).
4. Displays the alarm code relating to pipe guide numeric control (*).
5. Displays the alarm code relating to pipe guide arm numeric control (*).
(*) For more detailed information on the IP 166 alarm messages, see enclosure 2
Screen 5/5
1. Page title
2. Reel 1 position degrees value
3. Reel 2 position degrees value
4. Pipe guide position degrees value
5. Pipe guide arm position degrees value
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3.2 parameter entering
This key allows the operator to display the data entering pages relating to the type of production to be carried out.
Screen 1/10
MAchINE PARAMETERS (1)
pipe diameter (mm) (2)
correction utensil arm (3)
reel 1 turrns for layer (4)
reel 2 turrns for layer (5)
MAchINE PARAMETERS (1)
reel 1 drum radius (2)
reel 2 drum radius (3)
max take-up speed (4)
max manual take-up speed (5)
Front view
Pipe guide
Arm toolmeasurement = 5mm
Pipe guide arm front view
Use and Service ManualMatr. 740 - 10.05
1. Page title (read only function).
2. Enter the diameter of the pipe to be coiled (in mm)
3. Indicates the tolerance value to avoid the pipe guide arm from touching the flan-
ges during the coiling stage. The value is obtained by calculating the difference
(in mm) between the maximum external pipe guide width and the pipe diameter
(See the picture)
4. Set the number of turns to be produced for each layer of coil on reel 1
5. Set the number of turns to be produced for each layer of coil on reel 2
Screen 2/10
1. Page title (read only function).
2. Set the drum radius (as mm) on reel 1
3. Set the drum radius (as mm) on reel 2
4. Set up the maximum take-up speed during the coiling stage. It is recommended
to match this speed to the extruder production speed
5. Set up the maximum manual take-up speed; the speed is still controlled by the
oscillating arm within the limits set up by the software
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MAchINE PARAMETERS (1)
pipe guide start degrees (2)
coiling mode on reel 1 (3)
coiling mode on reel 2 (4)
select counting mode (5)
Moving reel quarters
No. 5 Turns
USIng THe SoFTwa Re
Screen 3/10
1. Page title (read only function)
2. Shows the degrees where the pipe guide will start moving sideways; Set to 0°
(maximum delay) if tight windings are desired, 90° (minimum delay) when high
coiling speeds are achieved or looser windings are desired.
3. Sets up the type of coiling to be carried out on reel 1 (alternated 3-4-3, alter-
nated 4-3-4, offset 4-4-4). To select the type of coiling to be carried out, move
to the field, press the SHIFT key and simultaneously scroll the ARROW keys
to view the available options
4. Sets up the type of coiling to be carried out on reel 2 (alternated 3-4-3, alter-
nated 4-3-4, offset 4-4-4). To select the type of coiling to be carried out, move
to the field, press the SHIFT key and simultaneously scroll the ARROW keys
to view the available options
5. Sets the coiling end mode.
If the option “REVOLUTIONS” has been selected, the reel will stop after
reaching the number of revolutions set; if selected in “METRES”, the reel will
stop after the number of metres set is reached
L = (n O ) L = (n O ) L = (n O + 1/2 Ø )
O O 1/2 O O
Variant 1 Variant 2 Variant 3
L = coil width
P = Pipe guide pitch
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VARIANTE 1alternated 3-4-3
Type of coiling
VARIANTE 2alternated 4-3-4
VARIANTE 3offset 4-4-4
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MAchINE PARAMETERS (1)
reel 1 coiling metres (2)
reel 2 coiling metres (3)
reel 1 coiling number of revolutions (4)
reel 2 coiling number of revolutions (5)
MAchINE PARAMETERS (1)
final cutting degrees on reel 1 (2)
final cutting degrees on reel 2 (3)
tail degrees (4)
tail positioning speed (5)
latching reel degrees (6)
MAchINE PARAMETERS (1)
arm latching value on reel 1 (2)
arm latching value on reel 2 (3)
reel 1 ejectors motion delay (4)
reel 2 ejectors motion delay (5)
MAchINE PARAMETERS (1)
slide down delay on reel 1 (2)
slide down delay on reel 2 (3)
number of coils for quality control (4)
dual strappings OK status (5)
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USIng THe SoFTwa Re
Screen 4/10
1. Page title (read only function)
2. Sets the number of metres reel 1 will be coiling before starting to cut the pipe;
this function is enabled only if the type of coiling has been set to “metres”
3. Sets the number of metres reel 1 will be coiling before starting to cut the pipe;
this function is enabled only if the type of coiling has been set to “metres”
4. Sets the number of revolutions to be made by reel 1 before starting the cutting
operation
5. Sets the number of revolutions to be made by reel 2 before starting the cutting
operation
Screen 5/10
1. Page title (read only function)
2. Allows reel 1 to be stopped on the desired degrees; this function can be ena-
bled only if the type of winding has been set to “revolutions”
3. Allows reel 2 to be stopped on the desired degrees; this function can be ena-
bled only if the type of winding has been set to “revolutions”
4. Enter the value in degrees which establishes the pipe final cut to achieve the
tail during strapping. When “0” is entered, the parameter is disabled
5. Enter the speed reached by the reel to position itself to obtain the tail on the
strap
6. Enter the reel positioning value, in degrees, where the pipe should be
latched
Screen 6/10
1. Page title (read only function)
2. Sets the value (in mm) at which the pipe guide arm will be positioned to latch
the pipe during the closing operation on reel 1.
The value is referenced from the reel central axis value
3. Sets the value (in mm) at which the pipe guide arm will be positioned to latch
the pipe during the closing operation on reel 2.
The value is referenced from the reel central axis value
4. Sets the time the coil will be held by reel 1 ejectors against the fixed flange
(in sec.)
5. Sets the time the coil will be held by reel 2 ejectors against the fixed flange
(in sec.)
Screen 7/10
1. Page title (read only function)
2. Sets reel 1 slide descent time to ease coil exiting. Set the value (in sec) accor-
ding to the features of the coil (width, weight etc.)
3. Sets reel 2 slide descent time to ease coil exiting. Set the value (in sec) accor-
ding to the features of the coil (width, weight etc.)
4. Sets how often the coiling machine will automatically eject, without strap-
pings, a section of pipe around 1 metre long, for quality control purposes.
The value entered shows the number of coils to be produced by the machine
before ejecting the pipe for quality control purposes (value 0…999). If set to
0, quality control operation is disabled
5. Enter the quarter where dual strappings must be carried out. Use the SHIFT
key and ARROW key to view the options available (all, none, 1st quarter, 2st
quarter, 3st quarter, 4st quarter, 5st quarter).
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MAchINE PARAMETERS (1)
No. of intermediate strappings (2)
Strapping machine forward moving time on reel 1 (3)
Strapping machine forward moving time on reel 2 (4)
MAchINE PARAMETERS (1)
number of final strappings on reel 1 (2)
number of final strappings on reel 2 (3)
strapping delay on reel 1 (4)
strapping delay on reel 2 (5)
MAchINE PARAMETERS (1)
coiling torque (2)
oscillating arm reading (3)
oscillating arm min value (4)
oscillating arm max value (5)
coiling operation with arm forward (6)
Use and Service ManualMatr. 740 - 10.05
USIng THe SoFTwa Re
Screen 8/10
1. Page title (read only function)
2. Sets how often the strapping device will carry out intermediate strappings to
achieve a more compact coiled pipe.
If set to 0, the parameter is disabled
3. Sets strapping machine forward moving time on reel 1 (as sec)
4. Sets strapping machine forward moving time on reel 2 (as sec).
Screen 9/10
1. Page title (read only function)
2. Sets the number of strappings on reel 1 (value 3, 4, 6)
3. Sets the number of strappings on reel 2 (value 3, 4, 6)
4. By selecting “YES” the first strapping operation will be carried out on reel 1
second quarter, thus staggering further strappings. Suitable for short coils
where the pipe section, after the cutting operation, is particularly long. NO =
first quarter (default).
5. By selecting “YES” the first strapping operation will be carried out on reel 2
second quarter, thus staggering further strappings. Suitable for short coils
where the pipe section, after the cutting operation, is particularly long. NO =
first quarter (default).
Screen 10/10
1. Page title (read only function)
2. Allows the reel coiling torque value (pulling force), shown as %, to be adju-
sted
3. Indicates a value directly proportional to the oscillating arm lifting value
4. Enter the minimum value when the arm sends the reel signal to start accele-
ration to take up the pipe
5. Indicates the maximum value when the oscillating arm will send the signal to
slow down the reel. When his threshold is exceeded, the oscillating arm will
stop at a value which is the automatically calculated average between the
minimum and maximum value
6. By setting the parameter to “YES”, the coiling operation will be carried out with
the pipe guard arm forward (default position). Set this parameter to “NO” when
pipe faults are noticed
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3.3 reserved pages
Use this key to access the set of reserved pages, whose parameters may be changed only after entering password of
level 2 or higher.
d a n g e r - a t t e n t i o n
AccESS TO ThESE PAGES IS ONLy ALLOwED TO quALIfIED STAff.
INAPPROPRIATE chANGES cAN jEOPARDISE ThE cOILING MAchINE OPERATION.
Screen 1/5
RESERVED PARAMETERS (1)
strapping machine strap throwing length (2)
strapping machine strap take-up length (3)
strapping machine strap take-up time (4)
strapping machine strap sealing time (5)
sensor
pulses
Roller and strap counter sensor
RESERVED PARAMETERS (1)
A1 drum format offset (2)
A1 flange format offset (3)
A2 drum format offset (4)
A2 flange format offset (5)
Use and Service ManualMatr. 740 - 10.05
1. Page title
2. Allows to set the length (in cm) of the strap thrown by the strapping machine
3. Allows to set the minimum strap take-up length, before enabling frictioning of
the take-up rollers
4. Allows to set up the strap take-up time before starting the pneumatically ope-
rated pulling stage. When the value is increased, the rollers will be operated
longer during the take-up stage.
5. Allows the pre-heating time during the strapping stage to be set.
(*) This value shows the number of pulses to be counted by the sensor; one
rotation of the roller corresponds to 18 pulses.
Screen 2/5
1. Page title
2. Enter a value (in mm) for the distance between the reel centre and the refe-
rence sensor (i.e. the maximum radius) for reel 1 drum maximum opening
3. Enter the value (in mm) for the distance between the fixed flange and the
reference sensor for reel 1 flange maximum opening
4. Enter a value (in mm) for the distance between the reel centre and the refe-
rence sensor (i.e. the maximum radius) for reel 2 drum maximum opening
5. Enter the value (in mm) for the distance between the fixed flange and the
reference sensor for reel 2 flange maximum opening
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RESERVED PARAMETERS (1)
pipe guide value on reel 1 internal area (2)
pipe guide value on reel 2 internal area (3)
pipe guide approaching value (4)
positioning speed (5)
RESERVED PARAMETERS (1)
disables strapping calculation (2)
disables pipe alarm (3)
disables battery alarm (4)
retract ejectors time for unloading (5)
oscillating arm alarm value (6)
RESERVED PARAMETERS (1)
reel 1 degrees (2)
reel 1 1000/mm degrees (3)
reel 2 degrees (4)
reel 2 1000/mm degrees (5)
arm mm (6)
USIng THe SoFTwa Re
Screen 3/5
1. Page title
2. Enter the value (in mm) for the pipe guide latching in relation to reel 1 fixed
flange
3. Enter the value (in mm) for the pipe guide latching in relation to reel 2 fixed
flange
4. Enter the pipe guide approaching value (in mm) during the latching stage
5. Enter the reel rotation speed during the strapping and opening stages
Screen 4/5
1. Page title
2. If set to YES, the strapping device will continue to repeat the strapping opera-
tion once started. This function is normally used during the testing stage. To
exit this stage, set the value to 0 (range YES, NO)
3. If set to YES, the pipe present monitoring operation carried out by the dedi-
cated sensor is bypassed. This is useful during the coiling machine testing
stage
4. Disables the machine stop function with the “PLC back-up battery memory
dead” alarm (range YES, NO).
By setting the value to YES when the alarm is displayed on screen, the
machine will continue to operate
5. Sets the time taken to fully retract the ejectors. Any delay, in combination with
the slide moving up, allows the coil to be vertically unloaded
6. Sets the threshold value to send an alarm signal (arm up, pipe stretched)
Screen 5/5
1. Page title
2. Allows the operator to carry of a zero reference adjustment for reel 1, in degrees
(useful, for example, if a motor or a reduction unit is replaced)
3. Allows the operator to carry out further adjustments, for reel 1 zero reference
point, in thousands of millimetres, to improve offset accuracy.
4. Allows the operator to carry of a zero reference adjustment for reel 2, in degrees
(useful, for example, if a motor or a reduction unit is replaced)
5. Allows the operator to carry out further adjustments, for reel 2 zero reference
point, in thousands of millimetres, to improve offset accuracy.
6. Allows the operator to carry out a zero reference point adjustment operation
for pipe guide arm, in degrees (useful if, for example, a motor or a reduction
unit is replaced)
d a n g e r - a t t e n t i o n
If A DEAD bATTERy IS NOT REPLAcED wIThIN 2 TO 3 DAyS, ThE PROGRAM DATA MAy bE LOST; fOR
INSTRucTIONS ON hOw TO REPLAcE A DEAD bATTERy AND/OR RESET ThE PLc PROGRAM, SEE PAR 3.1.2
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3.4 recipe management
This key allows the operator to access the “data set” page to enter or recall recipeS.
The recipes contain all the machine parameters; they are grouped as files, representing the different production
types. This allows each pipe production to have its coiling speed, number of strappings, stop at quarter etc. The time
initially taken to enter all the data relating to each type of pipe can ensure a huge time saving later on by requiring
the operator to simply press a single key to recall all previously set data.This page is protected by Level 2 password. To
enter data, a level 2 or higher password must therefore be entered. For more information on entering, printing and
transferring recipes, see chapter 8 of enclosure c-1.
(f7) recipeS - data Set
DATA SET (1)
Edit (f2) (2)
Print (f4) (3)
Transfer (f6) (4
01 REcIPES (1)
DATA SET (1)
Use and Service ManualMatr. 740 - 10.05
1. Page title
2. Press this key (F2) to access data entering and editing mode
3. Press this key (F4) to access data printing mode (connect the RS232/TTY IF2
port to a printer)
4. Press this key (F6) to access “data transfer” to PLC mode
(f2) enter/edit data (1/4)
1. Use the “arrow” key to move to this field and confirm it by pressing “enter”
key to access the reserved pages parameters.
enter/edit data (2/4)
1. Default recipe.
Confirm the recipe by pressing the “enter” key. By doing so, the pages
containing the reel parameters or the reserved pages can be accessed. The
parameters are described in the previous pages. By default, these have been
reset. Set the values according to the various type of pipes to be produced.
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01 Diameter = mm XX.X
02 Turns for layer = XX
03 Type of coiling = XXX
………….
………….
………….
Nr. X (1)
Name XXXXXXXXXX (2)
Store XXXXXXX: S (3)
01 REcIPES
01 Pipe 16 (1)
02 Pipe 32 (2)
03 Pipe 40 (3)
………………….
………………….
………………….
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enter/edit data (3/4)
This page contains all the parameters relating to reel production. Use the
SeLection arroW inside the field ad confirm the data entered with the enter
key. Some values, particularly alphanumeric values, require the Shift key to be
pressed together with the SeLection arroWS. After all values have been
entered, press eSc twice.
enter/edit data (4/4)
1. Increasing number relating to the files (recipes) stored. Confirm the data ente-
red with the enter key. Move to the following item by using the SeLection
arroWS
2. Recipe name. To enter it, press the Shift key and set the name with the
SeLection arroWS (such as pipe 32). Move to the next item with the
SeLection arroWS
3. Storing the entered recipe name. Press enter to confirm the recipe storing
operation. To exit, press the eSc key until the main page is displayed
(f4) print recipeS (1/2)
After selecting the print item with key (F4) from the previous page (recipes),
select reel 1 or 2 recipes by using the SeLection arroWS, then confirm with
the enter key.
print recipeS (2/2)
Recipe list (if stored). Select the recipe to be printed by using the SeLection
arroWS, then confirm your selection with the enter key.
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01 REcIPES
Source: (1) Dest: (2)
XXXXXXXXX (3)
Confirmation (4)
PLC: ##### (5) OP: 1 (6)
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USIng THe SoFTwa Re
(f6) tranSferring recipeS (1/2)
After selecting the tranSfer menu item with the key (f6) from the previous
page (recipes), select reel 1 or 2 recipes by using the SeLection KeYS and
confirm the selection with the enter key.
tranSferring recipeS (2/2)
1. Number of the recipe to be transferred
2. Destination of the recipe to be transferred (default)
3. Name of the selected recipe
4. Confirmation field
5. Read only field (default)
6. Read only field (default)
In the Source (1) field, enter the sequenced number of the recipe to be transferred
and confirm the entry by pressing the enter key. Field 3 will display the sequen-
tial number selected. By using the SeLection arroWS, move to the flashing
field confirm (4), then confirm the selection by pressing the enter key. Check
that the selected recipe has effectively been transferred from the main pages.
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3.4.1 creating a typical recipe
The recipeS are files containing all the parameters relating to a specific type of coiling operation.The sections below describe in
details how to manage the different recipes and to manage production easily and effectively.
After entering a Level 2 password, press f2 to access the
“machine parameters” page
Enter the data relating to the production to be carried out (pipe diameter, turns etc) navigating with the cursor keys and
enabling, where required, the alphanumeric keyboard by pressing the SHIFT key (green LED on). Confirm each entry with the
enter key
After entering all the required data, press f7 to access the “data set” page
Select the “transfer” item by pressing f6 DATA SET
Edit (F2)
Print (F4)
Transfer (F6)
When on menu item “01 machine parameters”, confirm the selection with the enter key
When on menu item “Source”, confirm the value “0” *(parameters entered
page) by pressing the enter key
Move with the cursor to the item “deStination”
Enter the recipe sequential number (if stored, for ex. 04) and confirm it with
the enter key. The recipe will be assigned the name “04 data_set”
Move to the “confirmed” item, then confirm the selection by pressing the
enter key
Use and Service ManualMatr. 740 - 10.05
Source: 0 Dest:XXXXXXXXX
Confirm
PLC: ##### OP: 1
Source: 0 Dest:
XXXXXXXXX
Confirm
PLC: ##### OP: 1
Source : 0 Dest: 04
XXXXXXXXX
Confirm
PLC: ##### OP: 1
Source: 0 Dest: 04
XXXXXXXXX
Confirm
PLC: ##### OP: 1
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3.4.2 changing the title of a typical recipe
After entering a Level 2 password, press f2 to access the
“machine parameters” page
Enter the data relating to the production to be carried out (pipe diameter, turns etc) navigating with the cursor keys and
enabling, where required, the alphanumeric keyboard by pressing the SHIFT key (green LED on). Confirm each entry with the
enter key
After entering all the required data, press f7 to access the “data set” page
Select the “transfer” item by pressing f6 DATA SET
Edit (F2)
Print (F4)
Transfer (F6)
When on menu item “01 machine parameters”, confirm the selection with the enter key
If any stored recipes are displayed, move with the cursor to the number of the recipe just created (for ex. 04 data_set) and
confirm it by pressing the enter key. The parameters entered will be displayed
Exit the parameters mode by pressing eSc, move to the menu item “name”
and enter the new name associated with the production to be performed (for ex NO. X
diameter 32 - 50m). Remember to enable the alphanumeric keyboard with the NAME XXXXXXXXX
Shift key (green LED on). Confirm the selection by pressing the enter key STORE XXXXXXX: S
At the “store” menu item, validate your selection by pressing the enter key.
NO. X
NAME XXXXXXXXX
STORE XXXXXXX: S
Confirm the “overwrite” menu item selection by pressing the enter key, then press eSc or f1 to return to the main
page
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3.5 op17 main page (reserved page)
This key allows the operator to enable the Siemens OP17 operator terminal MAIN PAGE, which allows the operator
to access the keyboard system parameters. To access this page, a level 9 password must be entered. For a more
detailed description of the OP17 main page controls, read enclosure c-1 (op17 operator panel manual).
d a n g e r - a t t e n t i o n
AccESS TO ThESE PAGES IS ONLy ALLOwED TO quALIfIED STAff.
INAPPROPRIATE chANGES cAN jEOPARDISE ThE cOILING MAchINE OPERATION
(f8) op17 main page
(1) Page title (Read only)OP17 MAIN PAGE (1)
ServAlert (2) AlarmInd (4) Pages (6) DataSet (8)
StatVar (3) ForcVar (5) System (7) Password (9)
Use and Service ManualMatr. 740 - 10.05
(2) Servicing alerts (F1)
(3) Variables status (F2)
(4) Alarm indication (F3)
(5) Forcing variables (F4)
(6) Pages (F5)
(7) System (F6)
(8) Data set (F7)
(9) Password (F8)
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4. aLarmS
4.1 overview
When the PLC detects an operating fault, the operator terminal will display the alarm messages, contained in the special screen.
By pressing the heLp key, the type of fault can be checked. (The HELP window is enabled if the LED stays on, otherwise HELP
will not be available). To return to the active screen, press eSc. When an alarm occurs, proceed as follows:
1. check the type of alarm
2. verify the causes and try to remove them
3. reset the PLC alarm bit by pressing the reSet button on the control panel
4. press the acK key on the keyboard to remove the alarm from the screen
5. if the cause is due to some operating unit on the machine (such as REEL 1), press the associated memory key
(for ex. the run key K1 on reel 1)
Other alarm messages are displayed on the drive displays sent by the numeric control modules:
IP266 - REEL 1 IP267 - PIPE GUIDE
IP268 - REEL 2 IP269 - PIPE GUIDE ARM
For details on alarm or error messages, read the manual attached
4.2 alarm messages index
The main alarms are listed below.
aL. code (alarm code) identifies the type of fault detected by the PLC. This can be deleted by pressing the ACK key.
For a detailed explanation of the alarm and of the actions to take, see Section IV, chapter 5
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aL. code mem. code aLarm meSSage reSet
M170.0 0009 Irregular air pressure K1 or K9
M170.1 0010 PLC battery dead K1 or K9
M170.2 0011 Marker not connected K1 or K9
M170.3 0012 Pipe not present K1 o K9
M170.5 0014 Axes not synchronised K16
M170.6 0015 Cabinet fans thermal cut-out K1 or K9
M170.7 0016 Photocell guard K1 or K9
M172.0 0025 Strapping machine out of strap K6, K1 or K9
M172.1 0026 Strapping machine cut-out K6, K1 or K9
M172.2 0027 Strapping machine strap pulling cylinder K1 or K9, K7, K6
M172.3 0028 Strapping machine slotted gripper K1 or K9, K7, K6
M172.4 0029 Strapping machine failed throwing operation K1 or K9, K6
M172.5 0030 Strapping machine central gripper K1 or K9, K6
M172.6 0031 Strapping machine throwing time out K1 or K9, K6
M172.7 0032 Strapping machine third gripper K1 or K9, K7, K6
M173.0 0017 Strapping machine sealing spout down K1 or K9, K7, K6
M173.1 0018 Strapping machine large plate down K1 or K9, K7, K6
M173.2 0019 Strapping machine strap gripper K1 or K9, K7, K6
M173.4 0021 Strapping machine approaching K1 or K9
M173.5 0022 Strapping machine head forward movement K1 or K9
M173.6 0023 Strapping machine sideway movement K1 or K9
M177.0 0049 Reel 1 ejectors not ok K1
M177.1 0050 Coil not ejected on reel 1 K1
M177.2 0051 Reel 1 opening released K1
M177.3 0052 Reel 1 opening incorrect K1
M177.4 0053 Reel 1 incorrectly closed K1
M177.5 0054 Reel 1 motor drive K1
M177.6 0055 Pipe not latched on reel 1 K1
M177.7 0056 No pipe on reel 1 K1
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aL. code mem. code aLarm meSSage reSet
M178.0 0073 High oscillating arm K1 or K9
M178.1 0074 Ejection carried out with disabled strapping machine K5
M178.2 0075 Wrong coil width on reel 1 K1
M178.3 0076 Reel 1 slide K1
M178.4 0077 Reel 1 coil quality control K1
M178.5 0078 Check reel 1 flanges width K1
M179.0 0065 Reel 2 ejectors not ok K9
M179.1 0066 Coil not ejected on reel 2 K9
M179.2 0067 Reel 2 opening released K9
M179.3 0068 Reel 2 opening incorrect K9
M179.4 0069 Reel 2 incorrectly closed K9
M179.5 0070 Reel 2 motor drive K9
M179.6 0071 Pipe not latched on reel 2 K9
M179.7 0072 No pipe on reel 2 K9
M180.1 0090 Ejection carried out with disabled strapping machine K5
M180.2 0091 Wrong coil width on reel 2 K9
M180.3 0092 Reel 2 slide K9
M180.4 0093 Reel 2 coil quality control K9
M180.5 0094 Check reel 2 flanges width K9
M181.0 0081 Pipe guide cutter cylinder K1 or K9
M181.1 0082 Motor arm pipe guide cut-out K1 or K9
M181.2 0083 Pipe guide motor cut-out K1 or K9
M181.4 0085 Pipe guide arm forward motion cylinder K1 or K9
Note: As for reset buttons K1 or K9, their operation depends on the operation being performed on each reel (reset button
K1 for reel 1, reset button K9 for reel 2)
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FB TR1860 L1/6 Part IVPRacTIcaL gUIde To The USe oF The coILeR
1. CALCULATION OF COIL DIMENSIONS .....................................................................73
2. SETTING PRODUCTION vALUES ..............................................................................74
3. MEChANICAL ADjUSTMENTS .................................................................................. .773.1 Install the suitable gauge . . . 783.2 Manual adjustment of the pipe latching . . . 793.3 Manual adjustment Paddles and slides . . . 813.4 Flange width . . . 823.5 Drum diameter 823.6 Inserting the pipe . . . 83
4. STARTING UP PRODUCTION ..................................................................................84
5. ALARMS .................................................................................................................... .855.1 Overview . . . 855.2 Alarm messages index . . . 85
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1
1/2 O
W/h
h
Part IV Practical guide to the use of the coiler
FB TR1860 L1/6 coIL dIMeNSIoN1S
1. CALCULATION OF COIL DIMENSIONS
The Excel-based program developed by FB SpA and supplied with the machine can identify all the characteristic
measurements of the finished coil from three basic parameters. Enter the parameters in the yellow panes denominated:
• (A) External Pipe Diameter
• (B) Internal Coil Diameter
• (C) Number of Turns
E. G. BASIC VALUES CALCULATION OF COIL DIMENSIONS
(A)Ø
External PIPE 40Diameter
(B) (C)d
Internal COIL 400 Number ofDiameter TURNS
W
1 2 3 4
7W/h
W L
h h
Nr Total Meterslayers for Turn for Layer for Coil
1 12 2
Coil dimensions (mm)diamete r h/L height (h)
W L W
W
Var 3Offset 4-4-4Coil width
(flange width)L 375 (mm)
O ) L = (n O ) L = (n O + 1/2 Ø )
1/2 O
3 34 4
1 2 3 41 1,351 9,462 1,623 11,363 1,895 13,274 2,167 15,175 2,439 17,076 2,711 18,987 2,983 20,888 3,255 22,79
D
9,46 480W
20,82 56734,08 65349,25 74066,33 82685,30 913
106,19 1000128,98 1086
h
h
h h h
0,1333 50,00000,2488 93,30130,36 43 136,60250,4797 179,90380,5952 223,20510,7107 266,50640,8262 309,80760,9416 353,1089
O
TE 1 VARIANTE 2 Var 2
O
VARIANTE 3
9 3,527 24,6910 3,800 26,6011 4,072 28,5012 4,344 30,41
1 1,351 9,46
153,67 1173 1,0571 396,4102180,26 1259 1,1726 439,7114208,77 1346 1,2880 483,0127239,17 1433 1,4035 526,3140
9,46 480 0,1333 50,0000altenated 4-3-4
Coil width
(flange width)L 350 (mm)
L = (n O ) L = (n O ) L = (n O
O O 1/2 O
23456
+ 1/2 Ø )
8 O9
101112
1,623 9,741,895 13,272,167 13,002,439 17,072,711 16,27
7 2,983 20,883,255 19,533,527 24,693,800 22,804,072 28,504,344 26,06
19,19 567 0,2488 93,301332,46 653 0,3643 136,602545,46 740 0,4797 179,903862,54 826 0,5952 223,205178,80 913 0,7107 266,506499,69 1000 0,8262 309,8076
119,22 1086 0,9416 353,1089143,91 1173 1,0571 396,4102166,71 1259 1,1726 439,7114195,21 1346 1,2880 483,0127221,27 1433 1,4035 526,3140
VARIANTE 1 VARIANTE 2 VARIANTE 3
Var 1alternated 3-4-3Coil width
(flange width)L 375 (mm)
L = (n O ) L = (n O )
1 1,351 8,112 1,623 11,363 1,895 11,374 2,167 15,175 2,439 14,636 2,711 18,98
L = (n O + 1/2 Ø )
8,11 480 0,1333 50,000019,47 567 0,2488 93,301330,84 653 0,3643 136,602546,01 740 0,4797 179,903860,64 826 0,5952 223,205179,62 913 0,7107 266,5064
O O
7 2 ,9 838 3,255 O9 3,527
10 3,80011 4,07212 4,344
17,90 97,52 100022,79 120,31 108621,16 141,47 117326,60 168,07 125924,43 192,50 134630,41 222,90 1433
0,8262 309,80760,9416 353,10891,0571 396,41021,1726 439,71141,2880 483,01271,4035 526,3140
VARIANTE 1 VARIANTE 2
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VARIANTE 3
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2. SETTING PRODUCTION vALUES
SeTTINg PaRaMeTe S
The steps in the procedure for setting the coiler for a new type of production or for production changeover are
summarized in the pages that follow. For a detailed description of the system software see Part III, chapter 3.
Accessing the parameter entering page F2.
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diameter of the pipe to CoiL
SCreeN 1/10
eNteriNg SettiNgS
SeTTINg PaRaMeTe S
2 Enter the diameter of the pipe to coil.
maChiNe parameterS (1)
pipe diameter (mm) (2)
correction utensil arm (3)
reel 1 turrns for layer (4)
reel 2 turrns for layer (5)
iNterNaL CoiL diameter
SCreeN 2/10
eNteriNg SettiNgS
2 - 3
maChiNe parameterS (1)
reel 1 drum radius (2)
reel 2 drum radius (3)
max take-up speed (4)
max manual take-up speed (5)
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Ø
Enter (as mm) reel 1 drum diameter
(internal diameter of the coil to be coiled).
d
75
2
----N--° 5 SPIRE
------N----° 4 SPIRE
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Part IV Practical guide to the use of the coiler
FB TR1860 L1/6
CoiLiNg type
SCreeN 3/10
eNteriNg SettiNgS
maChiNe parameterS (1)
pipe guide start degrees (2)
coiling mode on reel 1 (3)
coiling mode on reel 2 (4)
select counting mode (5)
L = (n O )
O
Variant 1alternated 3-4-3
SeTTINg PaRaMeTeR 2S
3 - 4 Sets up the type of coiling to be carried out on reel 1 (alternated 3-4-3,
alternated 4-3-4, offset 4-4-4). To select the type of coiling to be carried
out, move to the field, press the SHIFT key and simultaneously scroll the
ARROW keys to view the available options
L = (n O ) L = (n O + 1/2 Ø )
O 1/2 O O
Variant 2 Variant 3alternated 4-3-4 offset 4-4-4
LeNgth of pipe to be CoiLed aNd Number of turNS
SCreeN 4/10
eNteriNg SettiNgS
2 - 3 Sets the number of metres reel 1 and reel 2 will be coiling before starting
maChiNe parameterS (1)
reel 1 coiling metres (2)
reel 2 coiling metres (3)
reel 1 coiling number of revolutions (4)
reel 2 coiling number of revolutions (5)
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to cut the pipe; this function is enabled only if the type of coiling has been
set to “metres”
4 - 5 Sets the number of revolutions to be made by reel 1 and reel 2 before
starting the cutting operation
L
4 TURNS
5 TURNS
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3. MEChANICAL ADjUSTMENTS
MechaNIcaL adjUSTMeN S
F1 Before making machanical adjustments, access to information screen and have all information con-cerning the adjustments to do.
iNformatioN SCreeN
SCreeN 1/5
Page 1 containing the reading parameters is only used to summarize GENERAL INFO
the parameters entered in the machine and to allow easy control of data
tr1860L1/6 - 740 (1) 12:02:25 (2) entered in the coiling parameter program.
12:09:05 (3)
coils produced (4)
metres of pipe coiled (5)
A1 number of revolutions (6)
A2 number of revolutions (7)
D A N g E R - A T T E N T I O N
SWITCH OFF THE COIL TO MAkE MECHANICAL ADjUSTMENT IN A SAFETy WAy
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3.1 Install the suitable gauge
Fit a gauge with a suitable size for the pipe to be coiled.
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3.2 Manual adjustment of the pipe latching
1. To achieve this, pipe latcher (A) plate must be replaced at
every production change according to the diameter of the
pipe to be produced, by removing the screws which fasten it
to moving flap (B).
2. Further changes to the latching position are achieved by
moving the device along axis y (vertically) on one of the
differently spaced out rear holes (C).
3. Adjust the pipe latching position in relation to the lower posi-
tion of the guide it slides along to achieve a distance lower
than 10mm so that when it closes, the reel does not clash
with the latch on the tile.
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B
B
A
A
C
C
<10 mm
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4. For regulation of hooking compression, calculate the a
distance x = (Ø) + (CC) - (Compr)
where: Ø is the tube diameter measurement
(CC) is the cylinder stroke measurement
compr is the value of pipe compression
a distance x compression between the position of the
hook and that of the shell. The value will be equal to the
pipe diameter measurement plus the length of the
hooking drive cylinder stroke (50 mm) minus the pipe
compression value.
E. g.
63 + 50 - 7,5 = 105,5The dimension must be measured from the end of the
casing with the reel closed, otherwise a 1 cm deviation
may be observed.
ø
MechaNIcaL adjUSTMeN S
CC
*
compr
C a u t i o n - P r e c a u t i o n
ChooSe, amoNg the SheLLS SuppLied With the maChiNe, thoSe moSt SuitabLe for CoVeriNg aLmoSt
the eNtire CirCumfereNCe of the drum. iNSert, beiNg Sure to LeaVe a SpaCe of about 10 Cm to
permit StrappiNg.
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3.3 Manual adjustment Paddles and slides
high paddle positionAdjust the transversal position of the paddle arm by referring to
the position that the coil queue end will take.
Slacken the paddles of both reel.A. Screw for the transversal adjustmentB. Reel 2 high paddleC. Reel 1 high paddle
Low paddle positionAdjust the transversal position of the paddle arm by referring to
the position that the coil queue end will take.
Slacken the paddle with the locking screws and slide it along
the support pin. Slacken the paddles of both reel.A. Screw for the transversal adjustmentB. Reel 2 low paddle
C. Reel 1 low paddle
In coils with even numbers of layers, the end of the pipe will
be aligned with the hooking group, while in coils with odd
numbers of layers the end will be on the opposite side with
respect to the pipe hooking group (see illustration).
Slide positionAdjust the slide crosswise position in relation to the centre of
the coil on both reels.
Slacken the tightening nut and move the slides along the sup-
port rods.
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MechaNIcaL adjUSTMeN S
C
C
B
B
A
A
B
C B
CA
A
even n° of layers odd n° of layers
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3.4 Flange width
The adjustment of the width of flanges (width of the coil) is com-
pletely automatic and it is managed by the PLC.
By setting the desired value through the format change device,
the flange width is automatically adjusted to set the length of
the coil to be wound.
3.5 Drum diameter
The adjustment of the diameter of the drum (internal diameter
of the coil) is completely automatic and it is managed by the
PLC.
By setting the desired value through the format change device,
the internal drum diameter is automatically adjusted to set the
internal diameter of the coil to be wound.
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+
-
-
+
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3.6 Inserting the pipe
The oscillating arm (A) is a device for regulating
machine coiling speed according to the approach
angle (B) (which will vary with pipe tension).
The pipe is to be introduced in a suitable ring (C)
placed at the base of the oscillating arm (A) and
must pass under the first sliding roll (D), which
can be adjusted by loosening the suitable screws
indicated in the figure.
Push the pipe until the meter counter wheel is
reached (D) then adjust the exiting roll (E), so as
to avoid up and down movements of the meter
counting wheel during coiling.
When small diameter pipes are being coiled,
the shoulder plate (F) must be adjusted so as to
keep the meter-counter wheel from jumping or
bouncing during coiling.
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MechaNIcaL adjUSTMeN S
F
- -
+ +
A
CE
D
B
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Part IV Practical guide to the use of the coiler
FB TR1860 L1/6 STaRTINg UP PRodUcTIoN
4. STARTING UP PRODUCTION
Now it is crucial to:
- Check that the machine reels are closed; if not, close by hand. -
Close the safety barriers all the way.
- Restore normal safety conditions: turn the key-operated selector to lock the bars in place and
return the key to the safety supervisor
- Place the main switch on ON (I) and check that the phase presence signalling lamps are
supplied.
Start the machine by pressing the MOTOR RESET button. The button is enabled approximately 10
sec. after turning on the main switch
Start the machine by keeping the button AIR RESET pressed for at least 5 sec. signalled by the
acoustic signal
After about 5 seconds from resetting air supply, press the ALARM RESET button
Press the ACK button from the operator terminal to reset the alarms displayed on the screen
z Press the K16 button from the operator terminal to synchronise the axes
x y
When K16 indicator light is switched off (after synchronisation has taken place) press K1 Run button,
+ then press K2 to carry out an ejection operation without strappings on reel 1
A2 Then press run button K9, then K10 to carry out an ejection operation without strappings on reel 2
+
A2 After the pipe has been ejected, the coiling machine will automatically stop. Press K1 and K9 to
+ start the coiling operation.
The machine starts working automatically. From now, the manual intervention is required only in case of anomalies.
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5. ALARMS
5.1 Overview
When the PLC detects an operating fault, the operator terminal will display the alarm messages, contained in the special screen.
By pressing the hELP key, the type of fault can be checked. (The HELP window is enabled if the LED stays on, otherwise HELP
will not be available). To return to the active screen, press ESC. When an alarm occurs, proceed as follows:
1. check the type of alarm
2. verify the causes and try to remove them
3. reset the PLC alarm bit by pressing the RESET button on the control panel
4. press the ACK key on the keyboard to remove the alarm from the screen
5. if the cause is due to some operating unit on the machine (such as REEL 1), press the associated memory key
(for ex. the run key k1 on reel 1)
Other alarm messages are displayed on the drive displays sent by the numeric control modules:
IP266 - REEL 1 IP267 - PIPE GUIDE
IP268 - REEL 2 IP269 - PIPE GUIDE ARM
For details on alarm or error messages, read the manual attached
5.2 Alarm messages index
The main alarms are listed below.
AL. CODE (alarm code) identifies the type of fault detected by the PLC. This can be deleted by pressing the ACk key.
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AL. CODE MEM. CODE ALARM MESSAGE RESET
M170.0 0009 Irregular air pressure k1 or k9
M170.1 0010 PLC battery dead k1 or k9
M170.2 0011 Marker not connected k1 or k9
M170.3 0012 Pipe not present k1 o k9
M170.5 0014 Axes not synchronised k16
M170.6 0015 Cabinet fans thermal cut-out k1 or k9
M170.7 0016 Photocell guard k1 or k9
M172.0 0025 Strapping machine out of strap k6, k1 or k9
M172.1 0026 Strapping machine cut-out k6, k1 or k9
M172.2 0027 Strapping machine strap pulling cylinder k1 or k9, k7, k6
M172.3 0028 Strapping machine slotted gripper k1 or k9, k7, k6
M172.4 0029 Strapping machine failed throwing operation k1 or k9, k6
M172.5 0030 Strapping machine central gripper k1 or k9, k6
M172.6 0031 Strapping machine throwing time out k1 or k9, k6
M172.7 0032 Strapping machine third gripper k1 or k9, k7, k6
M173.0 0017 Strapping machine sealing spout down k1 or k9, k7, k6
M173.1 0018 Strapping machine large plate down k1 or k9, k7, k6
M173.2 0019 Strapping machine strap gripper k1 or k9, k7, k6
M173.4 0021 Strapping machine approaching k1 or k9
M173.5 0022 Strapping machine head forward movement k1 or k9
M173.6 0023 Strapping machine sideway movement k1 or k9
M177.0 0049 Reel 1 ejectors not ok k1
M177.1 0050 Coil not ejected on reel 1 k1
M177.2 0051 Reel 1 opening released k1
M177.3 0052 Reel 1 opening incorrect k1
M177.4 0053 Reel 1 incorrectly closed k1
M177.5 0054 Reel 1 motor drive k1
M177.6 0055 Pipe not latched on reel 1 k1
M177.7 0056 No pipe on reel 1 k1
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AL. CODE MEM. CODE ALARM MESSAGE RESET
M178.0 0073 High oscillating arm k1 or k9
M178.1 0074 Ejection carried out with disabled strapping machine k5
M178.2 0075 Wrong coil width on reel 1 k1
M178.3 0076 Reel 1 slide k1
M178.4 0077 Reel 1 coil quality control k1
M178.5 0078 Check reel 1 flanges width k1
M179.0 0065 Reel 2 ejectors not ok k9
M179.1 0066 Coil not ejected on reel 2 k9
M179.2 0067 Reel 2 opening released k9
M179.3 0068 Reel 2 opening incorrect k9
M179.4 0069 Reel 2 incorrectly closed k9
M179.5 0070 Reel 2 motor drive k9
M179.6 0071 Pipe not latched on reel 2 k9
M179.7 0072 No pipe on reel 2 k9
M180.1 0090 Ejection carried out with disabled strapping machine k5
M180.2 0091 Wrong coil width on reel 2 k9
M180.3 0092 Reel 2 slide k9
M180.4 0093 Reel 2 coil quality control k9
M180.5 0094 Check reel 2 flanges width k9
M181.0 0081 Pipe guide cutter cylinder k1 or k9
M181.1 0082 Motor arm pipe guide cut-out k1 or k9
M181.2 0083 Pipe guide motor cut-out k1 or k9
M181.4 0085 Pipe guide arm forward motion cylinder k1 or k9
Note: As for reset buttons K1 or K9, their operation depends on the operation being performed on each reel (reset button
K1 for Reel 1, reset button K9 for Reel 2)
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ALDCOADE. sPLAy MEssAgE PROBABPLECAusLEs M. CODE
M170.0 Irregular air pressure 1) No compressed air 00092) Pressure switch fault E97.03) EV/G main solenoid valve fault4) No power + 0”
action: 1) Check the compressed air pressure and that the reset voltage command has been executed2) Check that the E97.0 input on the PLC is on; replace the pressure switch if necessary3) Check the operation of the main solenoid valve on the compressed air input unit, operated by the PLC + 0” supply;
if necessary, replace the solenoid valve and test the operation of KM1
reset: K1 or K9
M170.1 PLC battery dead PLC battery dead 0010
action: Replace the PLC battery
reset: K1 or K9
M170.2 Marker not connected 1) Marker cable may be broken 00112) Marker not connected
action: 1) Check continuity on marker cable and replace it if necessary2) Check the marker located on the side panel of the electrical/pneumatic system cabinet
reset: K1 or K9
M170.3 Pipe not present 1) No pipe to be coiled 00122) Faulty metre counter E97.3 sensor which detects if pipe is present
action: 1) Check that the pipe is correctly inserted in the metre counter2) By looking at the associated LED, check that the sensor detecting the metre counter position with the bracket down
does not enable input E97.3 of the PLC when the pipe is inserted; replace it if necessary
reset: K1 or K9
M170.5 Axes not synchronised Axes not synchronised 0014
action Synchronize axes by pressing the key K16
reset: K16
M170.6 Cabinet fans thermal cut-out 1) FR3 cabinet fans cut-out triggered 00152) Faulty fan
action: Reset the FR2 cabinet fans thermal cut-out switch, if the fan cannot be replaced
reset: K1 or K9
M170.7 Photocell guard 1) The photocell detecting coil ejection may be faulty 00162) The photocell may be obstructed3) Coil unloading probably unsuccessful4) Foreign body may be present on photocell
action: 1) Check that the photocell is correctly operating by means of associated inputs E112.5 and113.5 on the PLC2) Check that there are no obstacles. Periodically clean the glass and the associated reflective strip3) Check that the coil is being correctly unloaded and that there is no foreign body going in front of the photocell
reset: K1 or K9
M172.0 Strapping machineout of strap Strap may be faulty 0025
action: Repeat the strap throwing operating by pressing the relevant button on the control panel
reset: K6, K1 or K9
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ALDCOADE. sPLAy MEssAgE PROBABPLECAusLEs M. CODE
M172.1 Strapping machinecut-out 1) Strap throwing motor cut-out switch opened 00262) Faulty thermal resistor
action: Reset the FR5 Strapping machine motor cut-out; if this is not possible, test the electrical circuit and, if necessary,replace the faulty motor
reset: K6, K1 or K9
M172.2 Strapping machine 1) Obstacles may be present on the strap pulling device 0027strap pulling cylinder 2) E104.6 and E104.7 sensors may be faulty
3) Solenoid valve A104.7 may be faulty 4) There may be no air supplied or the dedicated pressure gauge is incorrectly set
action: 1) Remove the obstacle2) Check correct operation of sensors E104.6 and E104.7 by means of associated LEDs on the PLC;
replace them if necessary 3) Check correct operation of solenoid valve A104.7 by means of associated LED on the PLC; replace if necessary 4) Check that there is the minimum operating air pressure in the pneumatic circuit and that there is low voltage power supply 5) Check by means of the pressure gauge on the pneumatic control panel the correct pressure of the cylinder
dedicated to pulling the strap
reset: K1 or K9, K7, K6
M172.3 Strapping machine slotted gripper 1) Possible obstacles on the slotted gripper 00282) Solenoid valve on strapping device A104.1 may be faulty 3) Sensor on pneumatic cylinder E104.1 may be faulty
action: 1) Remove the obstacle2) Check the A104.1 solenoid valve is correctly operating and replace it if necessary 3) Check that sensor E104.1 is correctly operating and replace it if necessary 4) Check that the associated LEDs on the PLC are on, both for the sensor and for the solenoid valve 5) Check that there is air in the pneumatic circuits and that there is low voltage supply
reset: K1 or K9, K7, K6
M172.4 Strapping machine, 1) There may be obstacles on the strap guide channels 0029failed throwing operation 2) Strap may be defective
3) Sensor EW 36 may be faulty
action: 1) Remove the obstacle2) Carry out a strap cutting operation or try to carry out a new strap throwing operation3) Check that sensor EW 36 is correctly operating and replace it if necessary
reset: K1 or K9, K6
M172.5 Strapping machine, central gripper 1) Obstacles may be present on the central gripper 00302) Solenoid valve on strapping device A104.2 may be faulty 3) Sensor on pneumatic cylinder E104.2 may be faulty
action: 1) Remove the obstacle2) Check the A104.2 solenoid valve is correctly operating and replace it if necessary 3) Check that sensor E104.2 is correctly operating and replace it if necessary 4) Check that the associated LEDs on the PLC are on, both for the sensor and for the solenoid valve 5) Check that there is air in the pneumatic circuit and that there is low voltage supply
reset: K1 or K9, K6
M172.6 Strapping machine throwing time out Incorrect strap throwing operation 0031
action: Repeat the strap throwing operation by pressing the relevant button on the control panel
reset: K1 or K9, K6
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ALDCOADE. sPLAy MEssAgE PROBABPLECAusLEs M. CODE
M172.7 Strapping machine third gripper 1) Obstacles may be present on the third gripper 00322) Solenoid valve on strapping device A104.3 may be faulty 3) Sensor on pneumatic cylinder E104.3 may be faulty
action: 1) Remove the obstacle2) Check the A104.3 solenoid valve is correctly operating and replace it if necessary 3) Check that sensor E104.3 is correctly operating and replace it if necessary 4) check that the associated LEDs on the PLC are on, both for the sensor and for the solenoid valve 5) Check that there is air in the pneumatic circuit and that there is low voltage supply
reset: K1 or K9, K7, K6
M173.0 Strapping machine 1) Obstacles may be present when the sealing spout if moving down 0017sealing spout down 2) Solenoid valve on strapping device A104.4 and A104.5 may be faulty
3) Sensor on pneumatic cylinder E104.4 may be faulty
action: 1) Remove the obstacle2) Check the A104.4 and A104.5 solenoid valve is correctly operating and replace it if necessary 3) Check that sensor E104.4 is correctly operating and replace it if necessary 4) Check that the associated LEDs on the PLC are on, both for the sensor and for the solenoid valve 5) Check that there is air in the pneumatic circuit and that there is low voltage supply
reset: K1 or K9, K7, K6
M173.1 Strapping machine 1) Obstacles may be present whilst the large plate is descending 0018large plate down 2) Solenoid valve on strapping device A104.6 may be faulty
3) Sensor on pneumatic cylinder E104.5 may be faulty
action: 1) Remove the obstacle2) Check the A104.6 solenoid valve is correctly operating and replace it if necessary 3) Check that sensor E104.5 is correctly operating and replace it if necessary 4) Check that the associated LEDs on the PLC are on, both for the sensor and for the solenoid valve 5) Check that there is air in the pneumatic circuit and that there is low voltage supply
reset: K1 or K9, K7, K6
M173.2 Strapping machine strap gripper 1) Obstacles may be present on the strap gripper 00192) Solenoid valve on strapping device A33.2 may be faulty 3) Sensor on pneumatic cylinder E32.0 may be faulty
action: 1) Remove the obstacle2) Check the A33.2 solenoid valve is correctly operating and replace it if necessary 3) Check that sensor E32.0 is correctly operating and replace it if necessary 4) Check that the associated LEDs on the PLC are on, both for the sensor and for the solenoid valve 5) Check that there is air in the pneumatic circuit and that there is low voltage supply
reset: K1 or K9, K7, K6
M173.4 Strapping machine approaching 1) An obstacle may be present during the strapping machine approach 00212) Sensors E96.1 and E96.2 may be faulty3) Solenoid valve A96.2 may be faulty4) No air may be present
action: 1) Check that sensors E96.1 and E96.2 are working correctly by means of associated inputs on the PLC;replace them if necessary
2) Check that are no obstructions during the approach stage 3) Check that the solenoid valve controlled by output A96.2 on the PLC is operating correctly;
if necessary, replace the solenoid valve 4) Check that compressed air is being supplied, both to the main circuit and to the approach cylinder circuit
reset: K1 or K9
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AL. CODE DIsPLAy MEssAgE PROBABLE CAusEs MEM. CODE
M173.5 Strapping machine 1) Strapping machine head incorrectly positioned 0022head forward movement 2) Sensor E96.0 on the locating cylinder may be faulty
3) Faulty solenoid valve A96.0 and A96.14) No air may be supplied or dedicated air flow regulator may be incorrectly set
action: 1) Check that the strapping device head has retracted enough to activate the sensor located on the locating pneumaticcylinder, check that the sensor on the cylinder is correctly positioned
2) Check through the associated LED that the cylinder position sensor enables input E96.0 on the PLC; if necessary, replace the sensor
3) Check that the LED on the PLC of outputs A96.0 and A96.1 is illuminated 4) Replace solenoid valves A96.0 and A96.1 5) Check through the pressure gauge located on the pneumatic control panel that the strapping machine head is being
supplied with a correct pressure
reset: K1 or K9
M173.6 Strapping machine 1) Strapping machine not correctly positioned 0023sideway movement 2) Strapping machine faulty locating sensors E96.4 and E96.5
3) Faulty solenoid valve A32.2
action: 1) Check that the base of the strapping machine has moved sideways enough to activate the sensor andcheck the correct position of the sensor
2) Check through the associated LED that the cylinder position sensor enables input E96.4 and E96.5on the PLC; if necessary, replace the sensor
3) Check that solenoid valve controlled by output A32.2 of the PLC is working correctly; replace if necessary
reset: K1 or K9
M177.0 Reel 1 ejectors not ok 1) Possible obstruction along the ejectors travel 00492) Sensors E112.0 and E112.1 may be faulty 3) Solenoid valve A112.0 may be faulty 4) no air may be supplied or dedicated air flow regulator may be incorrectly set
action: 1) Check that there are no obstructions along the ejectors travel 2) Check that sensors E112.0 and E112.1 are correctly working on the associated inputs on the PLC;
if necessary, replace the sensors 3) Check that the solenoid valve controlled by output A112.0 on the PLC is operating correctly;
if necessary, replace the solenoid valve 4) Check that compressed air is being supplied, both to the main circuit and to the ejection cylinders circuit
reset: K1
M177.1 Coil not ejected on reel 1 1) An obstacle may be present during coil ejection 00502) Sensors E112.0 and E112.1 may be faulty 3) Solenoid valve A112.0 may be faulty 4) Air may not be supplied 5) The photocell detecting coil ejection may be faulty
action: 1) Check that there are no obstructions along the ejectors travel 2) Check that sensors E112.0 and E112.1 are working correctly by means of the associated inputs on the PLC;
replace them if necessary 3) Check that the solenoid valve controlled by output A112.0 on the PLC is working correctly; replace if necessary 4) Check that compressed air is being supplied, both to the main circuit and to the ejection cylinders circuit 5) Check correct operation of the photocell through the associated input E112.5 on the PLC
reset: K1
M177.2 Reel 1 opening released 1) Pneumatic unlocking cylinder may be faulty 00512) Sensor E32.4 located on reel 1 pneumatic locking cylinder is faulty3) Faulty solenoid valve A32.3
action: 1) Stop the machine by pressing the emergency stop button; manually operate the releasing cylinderby means of the top screw
2) Check by means of the associated LED that the releasing cylinder position sensor enables input E32.4 of the PLC3) Check that solenoid valve controlled by output A32.3 of the PLC is working correctly;
if necessary, replace the solenoid valve
reset: K1
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Matr. 740 - 10.05 91
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Part IV Practical guide to the use of the coiler
FB TR1860 L1/6
AL. CODE DIsPLAy MEssAgE
M177.3 Reel 1 opening incorrect
aLaR MS
PROBABLE CAusEs MEM. CODE
1) Reel 1 pneumatic opening cylinder is faulty 00522) Sensors E32.2 and E32.3 on the cylinder are faulty3) Faulty solenoid valve A32.0
action: 1) Stop the machine by pressing the emergency stop button and manually operate reel 1to check that is operates freely all along its travel
2) Through the associated LED, check that reel 1 locating cylinder sensors enable inputs E32.2 and E32.3 on the PLC; if necessary, replace the sensor
3) Check for correct operation of the solenoid valves controlled by output A32.0 on the PLC; replace if necessary
reset: K1
M177.4 Reel 1 incorrectly closed 1) Reel 1 pneumatic opening cylinder is faulty 00532) Reel 1 end of travel sensor E32.3 is faulty3) Faulty solenoid valve A32.0
action: See recommended action for error M177.3
reset: K1
M177.5 Reel 1 motor drive 1) Obstruction may be present during reel 1 coiling operation 00542) Reel 1 cut-out FR8 may have been triggered 3) Motor drive A1 protective circuit may have been operated 4) Change format cut-out FR6 may have being triggered
action: 1) Check that there are no obstructions during the coiling operation 2) Check if thermal cut-out FR8 has been triggered 3) Check if reel 1 motor drive protective circuit has been operated;
check the error message code on the display and read the manual supplied to the customer (enclosure 4) 4) Check if format change cut-out FR6 has been triggered
reset: K1
M177.6 Pipe not latched on reel 1 1) Reel 1 pipe latch is faulty 00552) Encoder metre counter detecting the presence of the pipe is faulty
action: 1) Check that the pipe latching bracket located inside the reel drum is correctly adjusted2) Check that the function encoder is operating correctly; replace it if necessary
reset: K1
M177.7 No pipe on reel 1 1) No pipe to be coiled 00562) Pipe detecting sensor E97.3 is faulty
action: 1) Check that the pipe is inserted correctly in the metre counter2) Through the associated LED, check that the sensor detecting the position of metre counter does not enable input E97.3
of the PLC when the pipe is inserted and the bracket is down; if necessary, adjust the sensor position or replace it
reset: K1
M178.0 High oscillating arm 1) Pipe twisted 00732) Oscillating arm sensor EW40 is faulty
action: 1) Free the oscillating arm from the twisted pipe2) Test the sensor which detects the position of the oscillating arm marked EW40;
if necessary, adjust the sensor position or replace it
reset: K1 or K9
M178.1 Ejection carried out with disabled Disabled strapping machine 0074strapping machine
action: Enable the strapping machine by pressing the associated key
reset: K5
Use and Service Manual
Matr. 740 - 10.05 92
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Part IV Practical guide to the use of the coiler
FB TR1860 L1/6 aLaRMS
AL. CODE DIsPLAy MEssAgE PROBABLE CAusEs MEM. CODE
M178.2 Wrong coil width on reel 1 After setting the parameters relating to the coil dimensions, 0075an unachievable width has been detected
action: Check the parameters set on reel 1
reset: K5, K13
M178.3 Reel 1 slide 1) There may be obstacles along the slide travel 00762) Sensor E32.5 may be faulty3) Solenoid valve A32.1 may be faulty4) No air may be supplied or air flow regulator may be incorrectly set
action: 1) Check that sensor E32.5 is operating correctly by means of associated input on the PLC;if necessary, replace the sensor
2) Check that there are no obstacles along the slide travel 3) Check that solenoid valve controlled by output A32.1 of the PLC is working correctly;
if necessary, replace the solenoid valve 4) Check that compressed air is being supplied both to the main circuit and to the slide cylinder circuit 5) With the pressure gauge located on the pneumatic control panel, check the correct pressure
of the slide operating cylinder
reset: K1
M178.4 Reel 1 coil quality control Pipe section automatically cut for quality control purposes 0077
action: Remove the cut section of pipe from reel 1 and reset the machine by pressing the reel 1 run key
reset: K1
M178.5 Check reel 1 flanges width Reel 1 flanges width no longer matches currently used measurement 0078
action: Perform a format change on reel 1
reset: K1
M179.0 Reel 2 ejectors not ok 1) Possible obstruction along the ejectors travel 00652) Sensors E113.0 and E113.1 may be faulty 3) Solenoid valve A113.0 may be faulty 4) No air may be supplied or air flow regulator may be incorrectly set
action: 1) Check that there are no obstructions along the ejectors travel 2) Check that sensors E113.0 and E113.1 are correctly working on the associated inputs on the PLC;
if necessary, replace the sensors 3) Check that the solenoid valve controlled by output A113.0 on the PLC is operating correctly;
if necessary, replace the solenoid valve 4) Check that compressed air is being supplied, both to the main circuit and to the ejection cylinders circuit 5) Through the pressure gauge located on the pneumatic control panel, check that the ejectors are correctly positioned
reset: K9
M179.1 Coil not ejected on reel 2 1) An obstacle may be present during coil ejection 00662) Sensors E113.0 and E113.1 may be faulty 3) Solenoid valve A113.0 may be faulty 4) Air may not be supplied 5) The photocell detecting coil ejection may be faulty
action: 1) Check that there are no obstructions along the ejectors travel 2) Check that sensors E113.0 and E113.1 are working correctly by means of the associated inputs on the PLC;
replace them if necessary 3) Check that the solenoid valve controlled by output A113.0 on the PLC is working correctly 4) Check that compressed air is being supplied, both to the main circuit and to the ejection cylinders circuit 5) Check correct operation of the photocell through the associated input E113.5 on the PLC
reset: K9
Use and Service Manual
Matr. 740 - 10.05 93
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Part IV Practical guide to the use of the coiler
FB TR1860 L1/6
AL. CODE DIsPLAy MEssAgE
M179.2 Reel 2 opening released
aLaR MS
PROBABLE CAusEs MEM. CODE
1) Pneumatic unlocking cylinder may be faulty 00672) Sensor E33.4 located on reel 2 pneumatic locking cylinder is faulty 3) Faulty solenoid valve A32.3
action: 1) Stop the machine by pressing the emergency stop button; manually operate the releasing cylinderby means of the top screw
2) Check by means of the associated LED that the releasing cylinder position sensor enables input E33.4 of the PLC; if necessary, replace the sensor
3) Check that solenoid valve controlled by output A33.3 of the PLC is working correctly; if necessary, replace the solenoid valve
reset: K9
M179.3 Reel 2 opening incorrect 1) Reel 1 pneumatic opening cylinder is faulty 00682) Sensors E33.2 and E33.3 on the cylinder are faulty3) Faulty solenoid valve A33.0
action: 1) Stop the machine by pressing the emergency stop button and manually operate reel 2to check that is operates freely all along its travel
2) Through the associated LED, check that reel 1 locating cylinder sensors enable inputs E33.2 and E33.3 on the PLC; if necessary, replace the sensor
3) Check for correct operation of the solenoid valves controlled by output A33.0 on the PLC; if necessary, replace the solenoid valves
reset: K9
M179.4 Reel 2 incorrectly closed 1) Reel 2 pneumatic opening cylinder is faulty 00692) Reel 2 end of travel sensor E33.3 is faulty3) Faulty solenoid valve A33.0
action: See recommended action for error M179.3
reset: K9
M179.5 Reel 1 motor drive 1) Obstruction may be present during reel 2 coiling operation 00702) Reel 2 cut-out FR9 may have been triggered 3) Motor drive A2 protective circuit may have been operated 4) Change format cut-out may have being triggered FR7
action: 1) Check that there are no obstructions during the coiling operation 2) Ceck if thermal cut-out FR9 (Reel 2) has been triggered 3) Check if reel 2 motor drive protective circuit has been operated; check the error message code on the display
and read the manual supplied to the customer (enclosure 4) 4) Check if format change cut-out FR7 has been triggered
reset: K9
M179.6 Pipe not latched on reel 1 1) Reel 1 pipe latch is faulty 00712) Encoder metre counter detecting the presence of the pipe is faulty
action: 1) Check that the pipe latching bracket located inside the reel drum is correctly adjusted2) Check that the function encoder is operating correctly; replace it if necessary
reset: K9
M179.7 No pipe on reel 2 1) No pipe to be coiled 00722) Pipe detecting sensor E97.3 is faulty
action: 1) Check that the pipe is inserted correctly in the metre counter 2) Through the associated LED, check that the sensor detecting the position of metre counter
does not enable input E97.3 of the PLC when the pipe is inserted and the bracket is down; if necessary, adjust the sensor position or replace it
reset: K9
Use and Service Manual
Matr. 740 - 10.05 94
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Part IV Practical guide to the use of the coiler
FB TR1860 L1/6 aLaRMS
AL. CODE DIsPLAy MEssAgE PROBABLE CAusEs MEM. CODE
M180.1 Ejection carried out with disabled Disabled strapping machine 0090strapping machine
action: Enable the strapping device by pressing the associated key
reset: K5
M180.2 After setting the parameters relating to the coil dimensions, an unachievable width has been detected 0091
action: Check the parameters set on Reel 2
reset: K9
M180.3 Reel 2 slide 1) There may be obstacles along the slide travel 00922) Sensor E33.5 may be faulty3) Solenoid valve A33.1 may be faulty4) No air may be supplied or air flow regulator may be incorrectly set
action: 1) Check that sensor E33.5 is operating correctly by means of associated input on the PLC;if necessary, replace the sensor
2) Check that there are no obstacles along the slide travel 3) Check correct operation of solenoid valve A33.1 by means of associated LED on the PLC; replace if necessary 4) Check that compressed air is being supplied both to the main circuit and to the slide cylinder circuit 5) With the pressure gauge located on the pneumatic control panel, check the correct pressure of the slide
operating cylinder
reset: K9
M180.4 Reel 2 coil quality control Pipe section automatically cut for quality control purposes 0093
action: Remove the cut section of pipe from reel 2 and reset the machine by pressing the “reel 2 run” key
reset: K9
M180.5 Check reel 2 flanges width Reel 2 flanges width no longer matches currently used measurement 0094
action: Perform a format change on reel 2
reset: K9
M181.0 Pipe guide cutter cylinder 1) Cutter stuck 00812) Sensors E112.6 and E112.7 on the cutter pneumatic cylinder are faulty3) Faulty solenoid valve A97.5
action: 1) Repeat the cut by operating the run control; if the cutter is still stuck, stop the machine by pressing the emergencystop button and remove the cause of the blockage
2) Check through the associated LEDs that the cutter pneumatic cylinder position sensors enable inputs E112.6and E112.7 on the PLC
3) Check that the solenoid valve operated by output A97.5 of the PLC is operating correctly; replace if necessary
reset: K1 or K9
M181.1 Motor arm pipe guide cut-out 1) Pipe guide FR11 arm motor cut-out was triggered 00822) Motor drive arm GT protective circuit operated
action: 1) Reset the pipe guide arm motor cut-out switch FR11 on the electrical control panel; if this is not possible, test the electrical circuit and, if necessary, replace the pipe guide motor drive
2) Stop the machine by pressing the emergency stop button and wait for around 60 seconds to reset the drive internal protective circuit; should the problem reoccur, please refer to the instruction manual supplied with the drive
reset: K1 or K9
Use and Service Manual
Matr. 740 - 10.05 95
5
Part IV Practical guide to the use of the coiler
FB TR1860 L1/6 aLaRMS
AL. CODE DIsPLAy MEssAgE PROBABLE CAusEs MEM. CODE
M181.2 Pipe guide motor cut-out 1) Pipe guide FR10 motor cut-out was triggered 00832) Motor drive GT protective circuit operated
action: 1) Reset the pipe guide motor cut-out switch FR10 on the electrical control panel; if this is not possible,test the electrical circuit and, if necessary, replace the pipe guide motor drive
2) Stop the machine by pressing the emergency stop button and wait for around 60 seconds to reset the drive internalprotective circuit; should the problem reoccur, please refer to the instruction manual supplied with the drive
reset: K1 or K9
M181.4 Pipe guide arm forward 1) An obstacle may be present along the pipe guide travel 0085motion cylinder 2) Sensors E97.1 and E97.2 may be faulty
3) An obstacle may be present on solenoid valve A97.2
action: 1) Check that there are no obstacles along the pipe guide arm motion cylinder travel2) Check that sensors E97.1 and E97.2 are working correctly by means of associated inputs on the PLC;
replace them if necessary3) Check that the solenoid valve controlled by output A97.2 on the PLC is operating correctly;
if necessary, replace the solenoid valve
reset: K1 or K9
Use and Service Manual
Matr. 740 - 10.05 96
FB TR1860 L1/6 Part VTecHnicAL ATTAcHMenT
A tecHnicAL AttAcHMent F.B.1 List electrical spare part and Electrical diagram (see the Cd-Rom enclosed)
2 List pneumatic spare part and Pneumatic diagram (see the Cd-Rom enclosed)
3 List mechanical spare parts and Exploded view (see the Cd-Rom enclosed)
4 List parts number componentry
B AttAcHMentPLC Manual (see the Cd-Rom enclosed)
IP266 PLC extract manual (see the Cd-Rom enclosed)
SIEMENS OP17 Manual keyboard (see the Cd-Rom enclosed)
KEB manual “Getting started” (*)
S4 KEB manual driver (*)
Brushless KEB servomotor instruction
KEB interference suppression filter
SIEMENS counter module instruction
SIEMENS 3TK2825 Safety combination instruction
SIEMENS 3RG72 photocell instruction
SIEMENS 3RG78 photocell instruction
SIEMENS 3RG78 modulo di controllo per fotocellula instruction
SITOP Siemens power supply instructions
SHIELD reed proximity sensor instructions
SaIET proximity sensor instructions
SaIET 0-10 V inductive sensor instructions
SMC airchecher (pressure switch) instructions
SIEMENS BUS digital input/output
SHIELD Iso proximity sensor instructions
ROTfIL digital temperature adjuster instructions
TWS modularized siren instructions
SIEMENS switch differential gear instructions
SDRC5-C10 scheda motor (format) SELEMa instructions (*)
Separated manuals
Use and Service Manual
Matr. 740 - 10.05
1Part V
Technical Attachment
FB TR1860 L1/6
List eLectricAL spAre pArt
N° SHEET aBBREVIaTION
1 1 fR0
2 1 fR1
3 1 fR2
4 1 fVM0, fVM1
5 1 GS1
6 1 GS2
7 1 HL0-HL1-HL2
8 1 HL0-HL1-HL2
9 1 HLSB5-HLSB7
10 1 NEON1
11 1 NEON1
12 1 NEON2
13 1 NEON2
14 1 SB0
15 1 SB1-SB2-SB3-SB4
16 1 XS1
17 1-2 fVa0-fVa1-fVa2-fVa3fVa4-fVa5-fVa6-fVa7
18 1-2 Ka0-Ka1-Ka2-Ka3Ka4-Ka5-Ka6-Ka7
19 1-2 KM0-KM1
20 1-2 SB5-SB6-SB7-SB8
21 2 BT1-BT2
22 2 CMT
23 2 CNE
24 2 EV1-EV2
25 2 fR3
26 2 HL02
27 2 HL02
28 2 HLSB8
29 2 SL1
30 2 SL2
31 2 TMP1
32 3 BT3-BT5
33 3 BT4-BT6
34 3 CNf3
35 3 CNf4
36 3 CRT
37 3 fS3
38 3 GS3
Use and Service ManualMatr. 740 - 10.05
eLecTRicAL DiAGR AM
DESCRIPTION CODE fB
SWITCH N 4P 63a IP2X SIE5TE251 fB20120059
SWITCH SIEM. 5SU3747-0KW16 fB20080001
SWITCH 1-1,6 SIEM. 3RV1011/1aa10 fB20070008
DIODE aNTID. 3RT1926-1CB00 SIEM fB20180002
aLIM. SITOP 5a 24VDC 6EP1333-2aa-00 fB20180001
SafETY DEVICE SIEM 3TK28251BB40 fB20100013
LaMP GREEN SIEM 5TG8035 fB20120013
LaMP SEGNaLaTION SIEM. 5TE5700 fB20120014
LaMP GREEN aCE 138G MaTSUSHITa fB20120012
PLafONIERa HYDRO aD-fT fL1X18W fB20120084
LaMP fLUOR. 18W/84 590MM fB20120085
LIGHT HYDRO aD-fT fL1X58W fB20120086
LaMP fLUOR. 58W/84 1500MM fB20120087
MUSHROOM TEL ZB4BS54 fB20120030
EMERGENCY OPERaTOR PaNEL aB800E1PYP5a1 fB20140001
RECEPTaCLE SHUKO 2P 16 a GW20205 fB20130005
MODULE LED + DIODE fIN.9902902499 24DC fB20180004
RELaY fINDER 553490240049 4 CONT SC 24 fB20060008
REMOTE CONTROL SWITCH 11 KW SIEM. 3RT1026-1BB40 fB20060002
PUSH-BUTTON aCE 1222 D.12 MaTSUSHITa fB20120010
fOTOC. TEMPORIZ. SIEM. 3RG7211-6MC00 fB20040003
WHEEL MET. ELTRa RH500C50S24P10X3JR fB20050001
CONNECT. fISSO 4P+T CK031 PLaST ILME fB20130004
COMPLET fUN CEB VH6500 fB20140002
SWITCH 5SY6502-7BB 2P 2a “C” 6Ka fB20070030
LaMP SIREN 27781 24 VDC fB20090005
MODULE INDIC. LIGHT BLUE SIRENE TWSf 6027701 fB20090008
YELLOW LED aCE 138Y MaTSUSHITa fB20120015
SWITCH 2 POLES VIMaR 08381 fB20120001
SELECT. 0-1 STaB. LUM. V. TELZB4BK1233 fB20120051
TEMPORIZZaTORE fINDER 87110240 fB20060001
fOTOC. TRaSMITT. SIEM. 3RG7821-7BG00 fB20040002
fOTOC. RICEVENTE SIEM. 3RG7821-7CD00 fB20040001
CONNETTORE X fOTOC. SIEM. 3RX1578 (3 POLI) fB20040006
CONN. SP M8CV5M 4X025 MM B fB20040029SIEM. 3RX1577 (4POLI)
RECEPTaCLE 1,5 MM COD. 113702 fB20130021
fUSES CH GG 10,3X38 COD.CH10/10GG fB20160058
CENTRaLINa SICUR.SIEM. 3RG7826-1CB1 fB20100014
1
1Part V
Technical Attachment
FB TR1860 L1/6
N° SHEET aBBREVIaTION
39 4 fR4-fR6-fR7
40 4 fR5
41 4 fVM2-fVM3-fVM4fVM5-fVM6-fVM7
42 4 KM2-KM3-KM4KM5-KM6-KM7
43 4 MTL1
44 4 RT1
45 4 SSR
46 4 T1
47 4 TR
48 5 Ef1-Ef2
49 5 MTf1-MTf2
50 6 CaBLE a1-CaBLE a2
51 6 fIL1-fIL2
52 6 fR8-fR9
53 6 MTa1-MTa2
54 6 U1-U2
55 7 fIL3-fIL4
56 7 fR10-fR11
57 7 MTGT-MTBR
58 7 U3-U4
59 8 B1
60 8 B2
61 8 E0
62 8 E1
63 8 fS1-fS2
64 9 E4-E5-E7-E8
65 9-10 E3-E6-E9-E12
66 10 E10-E11-E13
67 10 E14
68 11 IPD
69 11 IPS1-IPS2
70 11 IPW1
71 11-12 IP1-IP17
72 15-19 Ra1-Ra2
73 15-19 RBR
74 15-19 RGT
75 17 aRM
76 17 TaST
77 18 MS2
Use and Service ManualMatr. 740 - 10.05
eLecTRicAL DiAGR AM
DESCRIPTION CODE fB
aUT. SWITCH SIEM.2P 6a 6Ka 5SY6506-7BB fB20070037
SWITCH0,45-0,63 SI.3RV1011-0Ga10 fB20070001
DIODE aNTID. 3RT1916-1CB00 24-48 SIEM. fB20180003
REMOTE CONTROL SWITCH 4KW fB20060003SIEM. 3RT1016-1BB42
MOT. ELET. M. C63 4P KW 0,18 220 / 380 / 50 fB20020001(ELECTRO aDDa)
RESIST. UTC DI 2.7 L 38.1 120WaTT 12V USC. 90° fB20200021
RELaY a STaTO SOLIDO SSR D2425 fB20060041
TERMOREG. RX16M 48X48 MONERX16T4H1VM fB20200018
TRaSfORM. 200Va 230V SEC. 0-13-16-18 VOLTS fB20060055
ENCODER ELTRa EH63f50S8/24P10X3JR fB20050002
MOTOR C.C. SELEMa 2263(RC253 / 2) fB20020003
CaBLE X MOT. KEB CM8P M. 2,5 8MT fB20010047
INTERf. SUPPR. fILTER COD. 14.U4.00E-BM01 fB20030027
INT. MaGNET SIE 3P 25a 5SY6325-7BB fB20070038
SERVOMOTOR 14 N/M 62SM.200.3400 fB20020046
DRIVER 14 N/M COD. 62S4E103470 fB20030044
INTERf. SUPPR. fILTER COD. 10U400DBM01 fB20030003
INT. aUT. SIEMENS 5SY6306-7BB 3P C 6a fB20070031
SERVOMOTOR 1,15 NM COD. 32.SM.200.3400 fB20020004
DRIVER 1,15 N/M COD. 32.S4.D103470 fB20030002
BaTTERY PLC 6ES5980—0Ma11 fB20100004
BaTTERY OP17 6ES7971-1aa00-0aa0 fB20100011
PaNN. OP17 6aV3617-1JC00-0aX0 fB20100010
PLC SIEMENS 6ES5-095-8Ma05 fB20100001
fUSES CH GG 10,3X38 1a WEB 1421 fB20160021
SCHEDa POSIZION. 6ES5266-8Ma11 fB20100008
MOD. BUS VITE SIEMENS 6ES5700-8Ma11 fB20100006
BLOCCO EL. 16IN 16OUT 6ES5482-8Ma13 fB20100007
BLOCCO EL. CONT. VEL 6ES5385-8MB11 fB20100009
SENSOR INDUT. aNaLOG. Ra1PM/XVP fB20040010
SENSOR 08 MM 24VDC PNP Ea0PMU/3aP fB20040007
SENSOR 4 MM 24VDC PNP EB04TM/3aP fB20040009
SENSOR IN. 12 MM 24VDC SaIEa1PNPMU/3aP fB20040008
SIGNaL CaBLE KEB CS8P.M. 8 MT fB20010048
SIGNaL CaBLE KEB 8,5 MT fB20010046
SIGNaL CaBLE KEB CS6P.M. 6 MT fB20010044
ELECTRIC CaBINET TR1200-1200X1500X400 fB20140088
TOOLS BOX OP17 - DX fB20140038
BORNE 2,5 MMq GRaY 280/601 WaGO fB20160001
2
1Part V
Technical Attachment
FB TR1860 L1/6
N° SHEET aBBREVIaTION
78 18 MS3
79 18 MS6
80 18 MS8
81 18 MS9
82 18 MS10
eLecTRicAL DiAGR AM
DESCRIPTION CODE fB
BORNE 2,5 MMq DOP GR 280/519 WaGO fB20160003
BORNE 4 MMq G/V 281/607 WaGO fB20160004
BORNE 6 MMq GRaY 39062 LEGRaND fB20160009
BORNE 6 MMq G/V 39372 LEGRaND fB20160010
BORNE 6 MMq BLU 39302 LEGRaND fB20160024
To order the spare parts, identify the components in the electrical diagram attached to the manual
Use and Service Manual
Matr. 740 - 10.05 3
2Part V
Technical Attachment
FB TR1860 L1/6
List pneuMAtic spAre pArt
N° SHEET aBBREVIaTION
1 1 C0
2 1 EV/G
3 1 fIL1
4 1 fIL2
5 1 M0
6 1 PR
7 1 PT
8 1 RP0
9 1 VLV1-VLV2
10 1-2 B1
11 1-2-3-5-6-7-8-9 M1-M2-M3-M4-M5-M6+RP6M7-M8-M9-M10-M11
12 1-2-3-5-6-7-8-9 RP1-RP2-RP3-RP4RP5-RP6-RP7-RP8RP9-RP10-RP11
13 1-3 B2
14 1-4-5 B3-B4
15 1-6 B5, B6
16 1-7 B7
17 1-8 B8
18 1-9 RfL0-RfL70-RfL71
19 2 C1
20 2 C2
21 2 C3
22 2 C4
23 2 C5
24 2 C6
25 2 C7
26 2 C8
27 2-4-5 RfL1-RfL2-RfL22-RfL32
28 3 C20
29 3 C21
30 3 C22
31 3 C23
32 3 C24
33 3 RfL10
34 3-4-5 Ba1-Ba2-Ba3
35 3-4-5 RfL11-RfL12-RfL23RfL24-RfL25-RfL33RfL34-RfL35
Use and Service ManualMatr. 740 - 10.05
PneUMATic DiAGR AM
DESCRIPTION CODE fB
CYLINDER ISO 6431 D. 63 C. 60 MaGN. fB40010133
aVVIaTORE PROGRESS. EaV4000-f04-5Y0 fB40040048
fILTER MOD. SCaR. aUT. Eaf4000-f04D fB40040054
MICROfILTER DISOLEaT. aUT. EafD4000-f04D fB40040051
GaUGE 195003 0/10 BaR 1/8” D. 40 fB40050001
PRESSURE SENSOR PS1000-R06L fB40070001
COLLETTORE MULTIP. KM11-08-12-10 fB40040003
RIDUTTORE MODULaRE EaR4000-f04 fB40040049
MEC. VaLVE EVM130-f01-00 fB40060015
SOTTOBaSE PLUG-IN SS5Y5-45NfD-11B-C6 fB40060006
GaUGE 195003 0/10 BaR 1/8” D. 40 fB40050001
RIDUTTORE PRESS. EaR2060-f02 fB40040001
MaNIfOLD SS5Y5-20-07-00f 7 POSIZ. fB40060002
MaNIfOLD SS5Y5-20-06-00f 6 POSIZ. fB40060020
MaNIfOLD SS5Y5-20-04-00f 4 POSIZ. fB40060003
MaNIfOLD SS5Y7-20-05-00f 5 POSIZ. 1/4 fB40060026
MaNIfOLD SS5Y5-20-02-00f 2 POSIZ. fB40060041
REG. fL. aS2211f-02-08S 1/4” T. 8 fB40030007
CYLINDER C.B. D. 63 C. 10 MaGN. fB40010009
CYLINDER C.B. D. 40 C. 10 MaGN. fB40010010
CYLINDER C.B. D. 50 C. 15 MaGN. fB40010004
CYLINDER C.B. D. 40 C. 15 MaGN. fB40010011
MICRO CYL. ISO 6432 D. 20 C. 25 MaGN. fB40010015
CYLINDER C.B. D. 25 C. 20 MaGN. fB40010014
CYLINDER C.B. D. 32 C. 20 MaGN. fB40010013
CYLINDER C.B. D. 63 C. 100 MaGN. fB40010008
REG. fL. aS2201f-01-04S 1/8” T. 4 fB40030003
CYLINDER ISO 6431 D. 32 C. 750 MaGN. fB40010032
CYLINDER C.B. D. 63 C. 50 MaGN. fB40010007
CYLINDER C.B. D.25 C.05 MaGN. fB40010024
CYLINDER ISO 6431 D. 50 C. 400 MaGN. fB40010002
MICRO CYL. ISO 6432 D. 20 C. 120 MaGN. fB40010173
REG. fL. aS2211f-01-06S 1/8” T. 6 fB40030006
BLOCCHETTO DI aLIM. SY5000-38-1a fB40060021
REG. fL. aS2201f-01-06S 1/8” T. 6 fB40030002
1
2Part V
Technical Attachment
FB TR1860 L1/6
N° SHEET aBBREVIaTION
36 3-4-5-6-8 E/V20-E/V21-E/V22-E/V23E/V24-E/V25-E/V30-E/V31E/V32-E/V33-E/V34-E/V40E/V41-E/V42-E/V43-E/V44E/V50-E/V51-E/V52-E/V53E/V54-E/V55- E/V56-E/V57E/V70-E/V71
37 3-4-5-6-8 RfL13-RfL14-RfL20-RfL21RfL30-RfL31-RfL40-RfL41RfL60-RfL62
38 3-6 OR1-OR2-OR3
39 4-5 C30-C40
40 4-5 C31-C41
41 4-5 C32-C42
42 4-5 C33-C34-C43-C44
43 4-5 C35-C36-C45-C46
44 4-5 RfL22-RfL32
45 6 C50
46 6 C51
47 6 C52
48 6 C53
49 7 BB1-BB2
50 7 C60-C62
51 7 C61-C63
52 7 C64
53 7 E/V60-E/V61-E/V62E/V63-E/V64
54 7 RfL50-RfL51-RfL52-RfL53RfL54-RfL55-RfL56-RfL57
55 7 SCR
56 7 VLS1
57 8 C70-C71
58 8 VLS2-VLS3
59 9 C80-C81-C82-C83
60 9 E/V80-E/V81
PneUMATic DiAGR AM
DESCRIPTION CODE fB
SOLENOID VaLVE 5/2 MON. 2 SY5120-5Y0-C6f-q fB40060042
REG. fL. aS2201f-02-06S 1/4” T. 6 fB40030004
DISPOSITIVO OR LOG. EVR1210-f01 1/8” fB40070002
CYLINDER C.B. D.80 C.15 MaGN. fB40010145
CYLINDER C.B. D.40 C.05 MaGN. fB40010001
CYLINDER ISO 6431 D. 63 C. 700 MaGN. fB40010030
CYLINDER C.B. D.40 C.40 MaGN. fB40010005
CYLINDER C.B. D.63 C.30 MaGN. fB40010146
REG. fL. aS2201f-01-04S 1/8” T. 4 fB40030003
CYLINDER ISO 6431 D. 50 C. 75 MaGN. fB40010018
CYLINDER ISO 6431 D. 50 C. 1200 MaGN. fB40010130
CYLINDER ISO 6431 D. 50 C. 125 MaGN. fB40010017
CYLINDER ISO 6431 D. 63 C. 150 MaGN. fB40010034
BLOCCHETTO DI aLIM. SMC SY7000-38 fB40060060
CYLINDER ISO 6431 D. 80 C. 600 MaGN. fB40010027
CYLINDER ISO 6431 D. 80 C. 200 MaGN. fB40010031
CYLINDER ISO 6431 D. 100 C. 300 MaGN. fB40010131
SOLENOID VaLVE 1/4” MON. SY7120-5Y0- fB40060018
REG. fL. aS3201f-03-08S 3/8” T. 8 fB40030001
SCaRICO RaPIDO 1/2” fB40060053
VaLVOLa DI BLOCC SMC aSP530f-03- fB40060004
CYLINDER ISO 6431 D. 63 C. 300 MaGN. fB40010025
VaLVOLa DI BLOCCO SMC aSP430f-02- fB40060005
CYLINDER ISO 6431 D. 63 C. 500 MaGN. fB40010028
SOLENOID VaLVE 1/8” SY5320-5Y0-C6f-q fB40060046
To order the spare parts, identify the components in the pneumatic diagram attached to the manual
Use and Service Manual
Matr. 740 - 10.05 2
4codici senpLri codici cAn Bus
Part V Technical Attachment
FB TR1860 L1/6 cOMPOnenTRY
List pArts nuMBer coMponentrY
pArt MAccHinA c And operAtor pAneL codici VALVoLe
signAture coMponent pArt nuMBer coMponent code FB
PLC SIEMENS SIE6ES5905-8Ma05 S C-N9E94828 fB20100001
PaNEL OP17 SIE6aV3617-1JC00 S C-S6B28648 fB20100010
Motors
signAture coMponent pArt nuMBer coMponent code FB
77802 SERVOMOTOR 14.0 NM 62SM20034B0 fB20020074
120533
124890SERVOMOTOR 1.15 NM 32SM20034B0 fB20020065
261044
reduction geAr
signAture coMponent pArt nuMBer coMponent code FB
RED.MP 130-2-12-15-24-50-180-215 06310 fB30010047
driVers
signAture coMponent pArt nuMBer coMponent code FB
04020254 DRIVER 1,15N/M CODE 32S4D103470 fB20030002
02141589
01400990DRIVER 14,0N/M CODE 62S4E103470 fB20030044
01400997
Use and Service Manual
Matr. 740 - 10.05 1