HMI map

Hardwired buttons

Same four buttons on both machines. On vision they sit under the HMI screen.

• Cycle Start

  Green

  Press and hold to start the machine running sequence. The machine starts in Auto mode. Hold for three seconds on the final changeover checklist to start.

• Cycle Stop Reset

  Red

  Press to stop after the current cycle, or to clear active alarms and warnings. A second Cycle Stop Reset is above the e-stop on the sorter.

• System On

  Blue

  Press to power on from a powered-down state. After a door or e-stop trip, this resets the status bar. Lock all doors and clear alarms before resuming.

• Emergency Stop

  Red mushroom

  Immediately ceases all machine operations. Use Cycle Stop — not E-Stop — in all non-emergency situations. Reset by turning clockwise until the button pops up.

Punch angles

From the Punch screen (maintenance only).

• 350°–10°Top position / top dead center
• 190°–200°Clockwork position
• 180°Lowest position (tamp-bar reset)
• 360°Top dead center after tamp reset

Screens

• 4-1p.25

  Splash screen and status-bar colors

  First HMI page and red / yellow / green status meaning.

• 4-2p.26

  Main / home screen

  Lock, mode, controls, statistics, and status bar.

• 4-3p.27

  Screen select menu

  Grid of all HMI destinations.

• 4-4p.28

  Feeder sorter screen

  Start and stop feeder, sorter, and hopper processes.

• 4-5p.29

  System information screen

  Scan times, lifetime cycles, Dry Run and Run Out modes.

• 4-6p.30

  Web feed screen

  Jog, unwind, brake, and lining-usage reset.

• 4-7p.31

  Punch screen

  Maintenance punch jog, position, clockwork, tamp, vacuum, kickers.

• 4-8p.32

  Cap feed conveyors screen

  Infeed, outfeed, tool, and vision accumulator status.

• 4-9p.33

  Alarm history screen

  Scrolling log of warnings and alarms.

• 4-10p.34

  I/O screen

  Live input and output states.

• 4-11p.35

  Machine statistics screen

  PackML-style process states and dwell times.

• 4-12p.36

  Alarm diagnostics screen

  Select, enable, delay, count, and reset each alarm.

• 4-13p.37

  Recipe operations

  Select, copy, and save recipes while logged in.

• 4-14p.38

  Additional setup screens

  Clockwork, punch, web-feed times, fibers, and lanes.

Display numbers

From BerryLiner setup 9002153. Active Alarms is display 110; Diagnostics is 112.

• Startup1
• Main Screen2
• System Info6
• Counters7
• State Machine8
• State Machine Statistics9
• PDF Viewer10
• Manual Functions12
• Manual Functions 213
• Map15
• Cap Infeed16
• Liner17
• Punch18
• Recipe Select20
• PLC IO Screens - Network40
• PLC IO Screens - Page 141
• PLC IO Screens - Page 242
• PLC IO Screens - Page 343
• PLC IO Screens - Page 444
• Parameters 170
• Parameters 271
• Parameters 372
• Parameters 473
• Parameters 574
• Conveyors100
• Active Alarms110
• Alarm History111
• Alarm Diagnostics112
• Machine Modes115

Machine network

Subnet 255.255.255.0. Laptop port 10.10.10.10.

• LAPTOP/PROGRAMMING PORT

  10.10.10.10

• Ewon

  10.10.10.1

• IO Controls

  10.10.10.100

• Servos/Fibers

  10.10.11.100

• PANELVIEW

  10.10.10.101

• IOLM_2000 On Machine

  10.10.10.110

• Flex IO

  10.10.10.112

• IOLM_1900 In Cabinet

  10.10.10.113

• GC Safety Controller

  10.10.10.115

• Conveyor VFDs (Multi-Drive)

  10.10.10.121

• Conveyor VFDs (Multi-Drive)

  Not Connected

  10.10.10.122

• Conveyor VFDs (Multi-Drive)

  Not Connected

  10.10.10.123

• Conveyor VFDs (Multi-Drive)

  Not Connected

  10.10.10.124

• Conveyor VFDs (Multi-Drive)

  Not Connected

  10.10.10.125

• Sorter VFDs (Multi-Drive)

  Not Connected

  10.10.10.126

• Sorter VFDs (Multi-Drive)

  10.10.10.127

• Sorter VFDs (Multi-Drive)

  10.10.10.128

• Sorter VFDs (Multi-Drive)

  10.10.10.129

• Rewinder VFD

  10.10.10.130

• Web Feed Servo Drive

  10.10.11.114

• Punch Encoder

  10.10.11.115

• Keyence FO Amp Bank 1

  10.10.11.116

• Keyence FO Amp Bank 2

  10.10.11.117

Recipe conveyor indexes

Recipe_Working.VFD_Conveyor_Speed — rate in Hz. Slow slots sit at +5 of the run speed.

• Infeed Conveyor 1[1]
• Infeed Conveyor 2[2]
• Outfeed Conveyor[3]
• Re-Circ Conveyor[4]
• Infeed Conveyor 1 (Slow)[5]
• Infeed Conveyor 2 (Slow)[6]
• Outfeed Conveyor (Slow)[7]
• Re-Circ Conveyor (Slow)[8]
• Accumulator[11]
• Blower Vac[12]
• Vision Infeed Conveyor[13]
• Vacuum Conveyor[14]
• Accumulator (Slow)[16]
• Blower Vac (Slow)[17]
• Vision Infeed Conveyor (Slow)[18]
• Vacuum Conveyor (Slow)[19]

Cell comms (DINT[0])

Produced bits between liner, vision, and stacker. Stop bits also clear faults.

• 0

  Safetys Reset - Auto Mode Selected - Alarms Cleared

  Liner: Ready · Vision: Ready · Stacker: Ready

• 1

  In Producing Mode

  Liner: Producing · Vision: Producing · Stacker: Producing

• 2

  In Held Mode

  Liner: Held · Vision: Held · Stacker: Held

• 3

  Ok to Feed Caps from Upstream Equipment

  Liner: OktoFeed · Vision: OktoFeed · Stacker: OKtoFeed

• 8

  Start Signal for Lining Machine

  Stacker: Liner Start

• 9

  Stop Signal/Clear Faults for Lining Machine

  Stacker: Liner Stop

• 10

  Hold Signal for Lining Machine — after hold clears, Cycle Start must be given

  Stacker: Liner Hold

• 13

  Start Signal for Vision

  Liner: Vision Start · Stacker: Vision Start

• 14

  Stop Signal/Clear Faults for Vision System

  Liner: Vision Stop · Stacker: Vision Stop

• 15

  Hold Signal for Vision System — after hold clears, Cycle Start must be given

  Liner: Vision Hold · Stacker: Vision Hold

• 31

  Held on by Publisher

  Liner: CommsBit · Vision: CommsBit · Stacker: CommsBit