ARTEZEN Calybra User manual

ISTRUZIONE OPERATIVA
IO
300_EN
Troubleshooting alarms Volumetric Divider
"Calybra"
Foglio
1/13
Rev
00
Via Lago di Tovel, 14 - 36015 Schio (VI) - Italy
Tel [phone] Fax [phone]
Data
07/10/2019
Redatto
D.G. –G.G.
REV
DATA
DESCRIZIONE
FIRMA
\\Servcad\macchine\UT\2 Documenti\2.2 Istruzioni Operative
APPLICABILITY OF THE DOCUMENT
Serial
Number
(S/N)
Sales date
Machine
configuration
Limitation of this document
> 134E22
XXXF22
XXXG22
XXXH22
XXXI22
XXX..22
XXXZ22
Oct 2019
Touch screen
Control panel
“Memory pack”
option
No Limitations
= 054E22
= 091E22
>111E22
<132E22
Apr 2019
÷
Oct 2019
Touch screen
Control Panel
“Memory pack”
option
Alarms #205, #206, #207, #208, #211, #212,
#213 not recognized with specific icon, but
the effects of the anomaly and the
resolution of the problem correspond to
the document.
It is possible to update the operating logic
software (PLC + Touch Screen) to the latest
version.
<051E22
>060E22
<079E22
>094E22
<100E22
XXXD22
XXXC22
XXXB22
XXXA22
< April 2019
“Memory pack”
option
Alarms #205, #206, #207, #208, #211, #212,
#213 not recognized with specific icon, but
the effects of the anomaly and the
resolution of the problem correspond to
the document.
Some images on the Touch screen panel
may differ from the document.
Some reference marks for electrical
components may differ from the document.
< April 2019
Touch screen
Control Panel NO
“Memory Pack”
option
PannElectromechan
ical Control Panel
NOT applicable
Before carrying out any maintenance work on the machine, carefully read the instruction manual attached to the
machine and make sure you have understood its contents, especially with regard to the installation of the
machine, its connection to the power supply, maintenance.
Always refer to the electrical diagram of the machine, available inside the electrical box for more information about the
electrical connection, the electrical components, the analysis of the anomaly from the electrical point of view.

ISTRUZIONE OPERATIVA
IO
300_EN
Troubleshooting alarms Volumetric Divider
"Calybra"
Foglio
2/13
Rev
00
Via Lago di Tovel, 14 - 36015 Schio (VI) - Italy
Tel [phone] Fax [phone]
Data
07/10/2019
Redatto
D.G. –G.G.
REV
DATA
DESCRIZIONE
FIRMA
\\Servcad\macchine\UT\2 Documenti\2.2 Istruzioni Operative
ALARM NOTIFICATION
Situation/Alarms
Causes
Problem solving
Touch screen panel off
Power supply
missing;
Main switch “QS1”
off;
Power supply “GB”
damaged;
Check the power
supply on all 3 power
steps along the line
The control panel is not powered.
Check the fuse “FL5”;
Check the connection of the connector "J1" installed
externally to the machine on the lower front part;
Pull out the serigraphy plate of the control panel and check
the cable and connector connection to the touch screen
panel.
If none of the operations described above allows the
functionality of the control panel, move the fuse holder
clamp from the "STR N" position to the "STR Y" position
inside the electrical box to bypass the touch screen control
panel: press the "RESET" button and then "START" (if
present) to start processing. Press "RESET" or "START"
several times to select the 5 working speeds available in
this temporary mode. Press "RESET" or "START" for a few
seconds to stop working. In the case of the "MEMORY
PACK" option, disconnect connector "J3" and proceed in
restart mode with manual management of the weight
adjustment. See also Operating Instruction “IO0205”

ISTRUZIONE OPERATIVA
IO
300_EN
Troubleshooting alarms Volumetric Divider
"Calybra"
Foglio
3/13
Rev
00
Via Lago di Tovel, 14 - 36015 Schio (VI) - Italy
Tel [phone] Fax [phone]
Data
07/10/2019
Redatto
D.G. –G.G.
REV
DATA
DESCRIZIONE
FIRMA
\\Servcad\macchine\UT\2 Documenti\2.2 Istruzioni Operative
Machine ready for "RESET"
The touch screen panel shows the
screen above: press the "RESET"
button to access the machine
functions. If pressing the "RESET"
button does not allow access to the
machine's functions, check:
Fuse "FL4" is broken;
Replace it with an equivalent one, which should be
available inside the electrical box.
The "ET1" safety
controller is damaged:
there is a voltage
between 'A1' and 'A2'
but the upper
"SUPPLY" led does
not light up.
The "ET1" control unit must be replaced.
The "ET1" safety
controller is damaged:
there is a voltage
between 'A1' and 'A2',
the upper led
"SUPPLY" lights up,
but the "RESET" is not
yet possible
- Disconnect wires '313' and '316' and jumper contacts
"S11" and "S34" of the safety controller: If the "RESET" is
now enabled, move on to the next step, otherwise the
"ET1" control unit must be replaced.
RESET" button
("SB4") damaged.
Check the CONTINUITY between wires '313' and '314'
while the "RESET" button is pressed. If there is continuity
between these wires (with "RESET" pressed), go to the
next step, otherwise replace the button.
Contactors "KM1" and
"KM2" damaged
Check continuity between '314' and '315' on "KM1" and
between '315' and '316' on "KM2": If there is continuity, the
control unit "ET1" is definitively damaged and must be
replaced, but if there is no continuity, replace the
contactors "KM1" and "KM2".
Interruption of
emergency circuit
The 24 VDC voltage between 'L308' and '-M', and between
'M308' and '-M'.
If there is no voltage, the emergency circuit is interrupted
at some point, so it is necessary to check the 24 VDC
voltage between '-M' and an intermediate point on the
circuit diagram along the line of the emergency circuit
between "FL4" and the control unit "ET1". (e.g. '-M' and
'L307, '-M' and 'M305' and so on to identify the unenabled
area).
Machine ready for "START"
Press the "START" button to start working

ISTRUZIONE OPERATIVA
IO
300_EN
Troubleshooting alarms Volumetric Divider
"Calybra"
Foglio
4/13
Rev
00
Via Lago di Tovel, 14 - 36015 Schio (VI) - Italy
Tel [phone] Fax [phone]
Data
07/10/2019
Redatto
D.G. –G.G.
REV
DATA
DESCRIZIONE
FIRMA
\\Servcad\macchine\UT\2 Documenti\2.2 Istruzioni Operative
ALARM # 120
“EMERGENCY STOP" button
pressed
The "STOP
EMERGENCY" button
is pressed
Turn the ring clockwise to unlock the button.
With the button unlocked, on the PLC "A1.0" the led #5
located in the area named "IN" on the PLC should be on. If
it is off: check the button contacts and the relative
connection wires 'L304' and 'L305'.
The remote button
"STOP EMERGENCY"
(if originally equipped)
is pressed or
disconnected.
Turn the ring clockwise to unlock the button.
Check the connection of the "J4" connector located in the
lower front part of the machine.
With the button unlocked, on the PLC "A1.0" the led #5
located in the area named "IN" on the PLC should be on. If
it is off:
ocheck the button contacts and the relative
connection wires 'L305' and 'L306'.
ALARM # 116
ALARM # 115
Intervention on thermal circuit
breakers
Supply voltage lower
than nominal. Usually
the engine overheats
easily.
If the voltage is lower than the rated voltage but within - 10
Volts (compared to the rated value), increase the
maximum limit of thermal intervention. If the voltage is
more than 10 Volts difference, replace all the motors,
based on the supply voltage in the installation room.
Lack of one of the 3
phases of the power
supply from the main
switchboard.
Check power supply to the panel on all phases;
Check "QF1" fuses
Check power supply on all phases on terminal board U, V,
W inside the terminal board of electric motors
Electric motor
damaged.
Usually the engine
overheats easily and it
could generate internal
vibrations.
Check the resistivity balance Ωof the windings, which
should be homogeneous;
Check the balance of power consumption on the 3 phases
of power supply;
Check that on all the 3 phases of the power supply the
electrical consumption (Ampere) is lower than the value
declared on the motor identification plate..
Mechanical
transmission problem
such that the torque
supplied by the motor
is not able to generate
the movement
Check the bearings, any gearboxes, etc.

ISTRUZIONE OPERATIVA
IO
300_EN
Troubleshooting alarms Volumetric Divider
"Calybra"
Foglio
5/13
Rev
00
Via Lago di Tovel, 14 - 36015 Schio (VI) - Italy
Tel [phone] Fax [phone]
Data
07/10/2019
Redatto
D.G. –G.G.
REV
DATA
DESCRIZIONE
FIRMA
\\Servcad\macchine\UT\2 Documenti\2.2 Istruzioni Operative
ALARM # 118
Open hopper and/or pressed
safety bar
Safety ring placed on
the edge of the hopper
and pressed down by
an external unit (e.g.
tipper hopper of the
kneader)
Make sure that the safety ring is free from any external
elements.
Safety ring limit switch pressed down due to lack of spring
support
Limit switch key damaged
Loose limit switch
Safety ring located on
the edge of the hopper
damaged in its shape,
so that one of the two
limit switches is always
pressed
Ensure that the geometry of the ring conforms to the
original geometry
Electromechanical
safety ring detection
limit switches,
damaged
Check that the pin supporting the circlip can slide
vertically.
Check limit switch contacts
Safety ring suspension
springs damaged,
blocked in movement,
or no longer able to
provide the necessary
support
Check that the springs are clean and free them from any
residual dough
Replace the springs
Electrical connection
of damaged limit
switch
With the safety ring NOT pressed down, on the PLC "A1.0"
the led #3 placed in the area called "IN" on the PLC should
be on. If it is off:
ocheck continuity between '+L4' and 'L302' on "SQ1"
and between 'L302' and 'L303' on "SQ1.1".
ALARM # 119
Open weight drawer access door
Limit switch key
damaged
Check that the key installed on the door is not damaged or
loose, or misaligned with respect to the seat of the switch
"SQ2".
Slack "SQ2" limit
switch
Check that the limit switch, integral with the warhead
inside the weight chamber, is well fixed on its support.
Electrical connection
of damaged limit
switch
With the door closed, on the PLC "A1.0" the led #4 located
in the area called "IN" on the PLC should be on. If it is off:
oCheck continuity between 'L303' and 'L304' on "SQ2".
ALARM # 121
Roller cover open
Limit switch key
damaged
Check that the key installed on the door is not damaged or
loose, or misaligned with respect to the seat of the switch
"SQ3".
Slack "SQ3" limit switch
Check that the switch, integral with the frame, is well fixed
on its support
Electrical connection of
damaged limit switch
With the door closed, on the expansion module of the PLC
"A1.2", LED #3 located in the area called "IN" on the
expansion module should be on. If it is off:
oCheck continuity between 'L306' and 'L307' on "SQ3".

ISTRUZIONE OPERATIVA
IO
300_EN
Troubleshooting alarms Volumetric Divider
"Calybra"
Foglio
6/13
Rev
00
Via Lago di Tovel, 14 - 36015 Schio (VI) - Italy
Tel [phone] Fax [phone]
Data
07/10/2019
Redatto
D.G. –G.G.
REV
DATA
DESCRIZIONE
FIRMA
\\Servcad\macchine\UT\2 Documenti\2.2 Istruzioni Operative
ALARM # 122
Safety protection for active
dough exit (only for CALYBRA L)
Limit switch key
damaged
Check that the key installed on the door is not damaged or
loose, or misaligned with respect to the seat of the switch
"SQ4".
Slack "SQ4" limit switch
Check that the switch, integral with the frame, is well fixed
on its support
Electrical connection of
damaged limit switch
With the door closed, on the expansion module of the PLC
"A1.2" the led #4 located in the area called "IN" on the
expansion module should be on. If it is off:
oCheck continuity between 'L307' and 'L308' on "SQ4".
ALARM # 143
Hydraulic power pack oil
overtemperature
Dirty heat exchanger
Clean the heat exchanger, using a jet of compressed air
directed inside the heat exchanger and outwards –Protect
the environment to avoid the making of dust in the work
area and protect the respiratory tract by using a suitable
protective mask
Heat exchanger fan
damaged
Check that with the machine on, the cooling fan rotates, also
checking that the air flow is facing outwards.
Damaged thermostat
Check on the PLC "A1.0" the led #13 placed in the area
named "IN" on the PLC should be on. If it is off:
oCheck continuity between '+L1' and '413' on "B1".
If the oil is at normal operating temperature, <50°C and the
alarm is active, bypass the thermostat signal TESTY until it
is replaced, by jumpering '+L1' and '413' to "B1" (general
terminal board).
Oil from the hydraulic
system to be replaced
Check that the oil in the plant has the characteristics
necessary for the operation of the machine, without showing
crystallization in its composition and its color has not
undergone significant changes.

ISTRUZIONE OPERATIVA
IO
300_EN
Troubleshooting alarms Volumetric Divider
"Calybra"
Foglio
7/13
Rev
00
Via Lago di Tovel, 14 - 36015 Schio (VI) - Italy
Tel [phone] Fax [phone]
Data
07/10/2019
Redatto
D.G. –G.G.
REV
DATA
DESCRIZIONE
FIRMA
\\Servcad\macchine\UT\2 Documenti\2.2 Istruzioni Operative
ALARM # 106
Proximity sensor "S1" not
detected
Sensor "S1" is
damaged or cannot
read its cam, or is
disconnected from the
connector, or its
connection to the PLC
is interrupted.
Check that the sensor is not physically damaged on its
outside;
Check that the sensor is well locked in place and that its
distance from the cam fixed to the splitting drum is NOT
more than 1 mm;
Check that the connector for the connection to the sensor is
well inserted and its ring nut is locked;
Check that on the PLC "A1.0" the led #10 located in the
area called "IN" on the PLC lights up when a metal element
approaches the end of the sensor.
To restore the machine's TEMPORARY working, by-passing
the above sensor, set internal parameter #6.2 to "ON".
Cyclic direction phases
reversed
There is a strong noise
coming from the
hydraulic unit and for
the Calybras equipped
with a split frontal
discharge, the two
coupled discharge
conveyors move in the
opposite direction to
each other.
The power supply phases are reversed with respect to what
is necessary. Follow the information in the instruction
manual to reverse the phases.
ALARM # 107
Proximity sensor "S2" not
detected
Sensor "S2" is
damaged or cannot
read its cam, or is
disconnected from the
connector, or its
connection to the PLC
is interrupted.
Check that the sensor is not physically damaged on its
outside;
Check that the sensor is well locked in place and that its
distance from the cam fixed to the dividing drum is NOT
more than 1 mm;
Check that the connector for the connection to the sensor is
well inserted and its ring nut is locked;
Check that on PLC "A1.0" LED #11 located in the area
called "IN" on the PLC lights up when a metal element
approaches the end of the sensor.
To restore the machine's TEMPORARY working, by-passing
the above sensor, set internal parameter #6.2 to "ON".
ALARM # 211
Proximity sensor "S2" not
detected when starting a new
work program (only for
CALYBRA with 'MEMORY
PACK')
Sensor "S2" is
damaged or cannot
read its cam, or is
disconnected from the
connector, or its
connection to the PLC
is interrupted.
Check that the sensor is not physically damaged on its
outside;
Check that the sensor is well locked in place and that its
distance from the cam fixed to the dividing drum is NOT
more than 1 mm;
Check that the connector for the connection to the sensor is
well inserted and its ring nut is locked;
Check that on PLC "A1.0" LED #11 located in the area
called "IN" on the PLC lights up when a metal element
approaches the end of the sensor.
To restore TEMPORARY operation, disconnect connector "J3"
and start manual mode, setting the break weight manually
using the manual adjustment handwheel.

ISTRUZIONE OPERATIVA
IO
300_EN
Troubleshooting alarms Volumetric Divider
"Calybra"
Foglio
8/13
Rev
00
Via Lago di Tovel, 14 - 36015 Schio (VI) - Italy
Tel [phone] Fax [phone]
Data
07/10/2019
Redatto
D.G. –G.G.
REV
DATA
DESCRIZIONE
FIRMA
\\Servcad\macchine\UT\2 Documenti\2.2 Istruzioni Operative
ALARM # 210
Slowing down machine
Working cycle time
higher than the
expected overall time
Overheating of the dividing drum surface which generates
drum rotation slowing down caused by high friction. It is
generally due to intensive work at maximum operating
speed, in a very hot environment. It is recommended to
reduce the operating speed for some time or to stop the
machining in order to allow the cooling of the splitting drum.
Clutch of the dividing drum too high due to the need to
adjust it (see operating instructions "IO0016").
Parameter 'Suction time' # 3.3 too long: do not exceed 0,7
Hard external element inside the hopper which hinders the
movement of the drum
Wrong type of hydraulic unit setting: act on parameter # 7.3
ALARM # 140
Oil hydraulic system too cold
Oil hydraulic system
too cold to start the
machine
Wait for the oil temperature to recover, leaving the machine
in the working environment for 24 hh
Check on the extension of the PLC "A1.2" the led #7 placed
in the area called "IN" on the PLC expansion should be off.
If it is on:
oDisconnect the 420 wire from the PLC and reset the
thermostat as soon as possible, reconnecting the
previously disconnected wire.
ALARM # 202
Workpiece counter sensor not
active
Sensor damaged
Physically check for possible damage to the structure of the
sensor located on the dough exit area, next to the product
delivery belt.
Sensor disconnected
from connector
Check that the sensor connector is well inserted and locked
by the fixing ring nut
Sensor not in line with
the reflector installed
on the side opposite to
the sensor
Verify that the axis of the sensor is aligned with the axis of
the reflection device located on the opposite side of the
sensor. Also check the locking of both.
Electrical connection
interrupted
Check that on PLC "A1.0" LED #7 located in the area called
"IN" on the PLC lights up following the interposition of an
element between the sensor and the reflector.
To by-pass automatic machine shutdown due to sensor failure, change underground
parameter #7.1 to "OFF". N.B.: Each time the machine's main switchboard is restarted,
this parameter must be reset, as it is considered a temporary situation.

ISTRUZIONE OPERATIVA
IO
300_EN
Troubleshooting alarms Volumetric Divider
"Calybra"
Foglio
9/13
Rev
00
Via Lago di Tovel, 14 - 36015 Schio (VI) - Italy
Tel [phone] Fax [phone]
Data
07/10/2019
Redatto
D.G. –G.G.
REV
DATA
DESCRIZIONE
FIRMA
\\Servcad\macchine\UT\2 Documenti\2.2 Istruzioni Operative
ALARM # 201
Workpiece counter sensor
always active
Dirty sensor or
reflection device
opposite the dirty
sensor
Thoroughly clean the sensor end and the reflection surface
of the device opposite the sensor
Machine restarted
several times after
automatic stop for lack
of dough
The machine must always work with the dough available in
the hopper
Reflection device
opposite the damaged
sensor
Check the reflective surface of the device
Selection of single pieces not in
conformity with the working
program (only for 'MEMORY
PACK')
Selecting double
divider
On machine with "MEMORY PACK" option, the position of
the lever that determines the type of single/double dividing
is not in conformity with the working program.
Sensor "S3" is
damaged or is unable
to read the relevant
cam (consisting of the
rod connected to the
dividing selection lever
Single/Double), or is
disconnected from the
connector, or its
connection to the PLC
is interrupted.
Check that the sensor is not physically damaged on its
outside;
Check that the sensor is securely locked in place and that
its distance from the rod connected to the Single/Double
Split Selection Lever is NOT more than 1 mm;
Check that the connector for the connection to the sensor is
well inserted and its ring nut is locked;
Check that on the PLC "A1.0" the led #12 located in the
area called "IN" on the PLC lights up following the approach
of a metal element to the end of the sensor.
To restore TEMPORARY operation, disconnect connector "J3"
and start manual mode, setting the dividing weight manually
by using the manual adjustment handwheel and positioning
the Single/Double dividing selection lever as desired.
Selection of double pieces not in
accordance with the work
program (only for 'MEMORY
PACK')
Selecting single divider
On machine with "MEMORY PACK" option, the position of
the lever that determines the type of single/double dividing
is not in conformity with the working program.
Sensor "S3" is damaged
or is always active when
it is activated by a
extraneous metallic
object or its holder has
loosened.
Check that the sensor holder "S3" is stable in its position
and that the sensor "S3" is locked in position.
Check, by rotating the single/double divider selection lever,
that the sensor is activated only with double divider,
adapting the sensing position of the sensor itself.
If the operation of adapting the reading of the sensor "S3" does
not solve the problem, to restore the TEMPORARY
operation, disconnect the connector "J3" and start the
manual mode, setting the weight of dividing manually by
acting on the handwheel manual adjustment and positioning
the lever for selecting dividing Single / Double as desired.

ISTRUZIONE OPERATIVA
IO
300_EN
Troubleshooting alarms Volumetric Divider
"Calybra"
Foglio
10/13
Rev
00
Via Lago di Tovel, 14 - 36015 Schio (VI) - Italy
Tel [phone] Fax [phone]
Data
07/10/2019
Redatto
D.G. –G.G.
REV
DATA
DESCRIZIONE
FIRMA
\\Servcad\macchine\UT\2 Documenti\2.2 Istruzioni Operative
Roller position selection not in
accordance with the working
program (only for CALYBRA L)
Move the roller assembly
in accordance with the
set double process
On the Calybra L version machine, the position of the
needle roller unit does not conform to the working set in
double section.
Limit switch "S4" not
detected, damaged, not
correctly fixed to the
support, or with
interrupted electrical
connection
Open the needle roller cover, then check the stability of the
switch and its mechanical function.
With the limit switch activated (needle roller group in forward
position 2 pcs) check on the expansion of the PLC "A1.2"
the led #2 located in the area named "IN" on the PLC
expansion should be on. If it is off:
Check wire entry 417
If necessary, replace the limit switch.
Roller position selection not in
accordance with the working
program (only for CALYBRA L)
Move the roller
assembly in
accordance with the set
double process
On the Calybra L version machine, the position of the
needle roller unit is not in accordance with the machining set
in single divider.
With the limit switch deactivated (needle roller group in rear
position 1 pc) check on the PLC expansion "A1.2" the led #2
placed in the area called "IN" on the PLC expansion should
be off. If it is on:
oIf necessary, replace the limit switch
The machine works correctly,
however, the product exit
conveyor(s), whose speed can be
modified, are stopped
Frequency converter
(inverter) shut down
exit conveyor drive in
emergency/shutdown
Check the electrical continuity of the inverter's protection
fuses, following the wiring diagram available inside the
electrical box
Check for possible alarm messages available on the display
on the inverter to find out the cause of the alarm. Given the
proliferation of versions, device updates, it is recommended
to consult the product online, through the manufacturer's
website