Fromm AP210 User manual

SERVICE-MANUAL
AIRPAD - MACHINE
AP210
AP21000101.sen/DS/© 05.12 v2.09
Manual for authorized resellers and service points
INDEX PAGE
1 PRELIMINARY REMARKS 2
2 WORKING PAGES 2
2.1 Working page 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Working page 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3 Working page 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.4 Working page 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.5 Working page 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 WORKING PAGE IN "MANUAL" 4
4 DIAGNOSTIC AND JOG PAGES 5
5 MACHINE PARAMETERS PAGE 8
6 PAGES FOR PARAMETER SETTINGS 9
7 PAGES FOR SELECTING OPERATIONAL SETTINGS 10
8 ALARMS 10

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Only trained and instructed personnel is authorized to perform servicing and
maintenance works!
1 PRELIMINARY REMARKS
The AP210 has been designed to be used easily by the operator. Therefore, the operator can only change the
number of airpads which are programmed by following the procedure described in paragraph 13.5 of the
Instructions for Use and Maintenance.
As for the remainder, the operator may scroll through the working pages and view the parameters
programmed but may not modify them, as this operation is reserved for technicians who have been issued a
password.
In order to view the version of the software in use push the buttons + .
There are two levels of intervention provided, each requires its own password:
PASSWORD USER 1492 - allows the modification of:
• Temperature of sealers;
• Inflation of airpads;
• Enabling or disabling the hopper.
PASSWORD TECHNICAL SUPPORT 6417 - allows the modification of:
• Temperature of sealers;
• Inflation of airpads;
• Length of airpads;
• Enabling or disabling the hopper;
• Entering programmes 7-8-9 or modifying the pre-set ones;
• Velocity of the cross sealer motor M1;
• Velocity of the film feeder motor M2;
• Velocity of airpad feeder M3;
• Sealing time of the cross sealer.
This is necessary because the inappropriate modification of even a single parameter can have adverse
effects on the functioning of the machine.
The following pages describe all parameters of the machine and the instructions on how to modify them.
2 WORKING PAGES
These are the pages which contain the main parameters for the operation of the machine.
2.1 Working page 1
Working page 1 is shown on the initial screen:
Page 1 shows:
- the state of the machine using the symbol whether it is in stand by or low energy consumption
,
- the alarm code, if an error has occurred,
- the summary of the programme being executed if the machine is in "run" mode:
length of airpads,
programme being executed,
airpads produced and total to be produced,
temperature of the cross and longitudinal sealers.

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Push the left or right arrow to scroll through the other working pages.
2.2 Working page 2
Page 2 shows:
• length of airpad,
• number of airpads programmed.
Procedure for changing parameters:
Push
The following screen appears:
Entering the password allows changing the programmed values (except for the same password given in the
preliminary remarks) by pushing the buttons and until the parameter to be changed is
highlighted, confirm with the button ,
move to the decimal to be changed and select it with the arrows or and change the values with
the buttons or .
Once the desired changes have been made, confirm with the button .
The password protected section is closed by pushing the button or automatically by
the machine after five minutes or by turning off the machine.
This procedure is the same for all parameters.
2.3 Working page 3
Working page number 3 shows (example):
In order to change the parameters refer to the procedure
described in paragraph 2.2
• 120° temperature of
longitudinal sealer
programmed;
• 27° actual temperature of
longitudinal sealer;
• 140° temperature of cross
sealer programmed;
• 40° actual temperature of
cross sealer;

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2.4 Working page 4
Working page number 4 shows the velocity of the vent for airpad inflation
as a percentage of the maximum value.
In order to change the parameter refer to the procedure
described in paragraph 2.2.
2.5 Working page 5
This page shows and allows to change the functioning of the machine in regards to the airpad collection
basket.
Depending on the activation or operating status of the hopper, the following symbols may appear:
Working page number 4 shows the operating mode of the machine relative to the hopper and allows to
change it.
In order to change the operating mode refer to the procedure described in paragraph 2.2.
3 WORKING PAGE IN "MANUAL"
The AP210 allows to activate the motors manually by opening the page "manual".
From the initial screen, or from the working pages if the machine is in stand by.
Push the button and the display shows the following:
With the button the motor of the cross sealer is activated clockwise, only if the protective guard is
closed.
Releasing the button stops the motor. If the protective guard is open, the upward arrow disappears from the
display and the cross sealer cannot be activated.
Machine with hopper activated Machine with hopper not activated

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With the button the motor of the cross sealer is activated anti-clockwise, only if the protective guard is
closed.
Releasing the button stops the motor. If the protective guard is open, the downward arrow disappears from the
display and the cross sealer cannot be activated.
With the button film advance is activated (only when the sealer is sufficiently open, otherwise, the
arrow disappears from the display). Releasing the button stops advance.
With the button film advance backwards is activated (only when the sealer is sufficiently open,
otherwise, the arrow disappears from the display). Releasing the button stops advance.
With the button the feeder for the cushions is activated to the forward setting.
With the button the vent for airpad inflation starts rotating, the numerical value shown on the display
indicates the velocity of the vent as a percentage of the maximum value.
Releasing the button stops the vent.
In order to exit from the "manual" mode, push this button again.
4 DIAGNOSTIC AND JOG PAGES
On these pages it is possible to control the status of the main parameters of the machine.
From the working pages push the buttons and , the following screen appears:
This page shows the status of the input connections according to the following table:
Index Signal/function Polarity
IN 1 Channel A encoder motor of sealer M1 ==
IN 2 Channel A encoder motor of film feeder
M2
==
IN 3 Channel B encoder motor of film feeder
M2
==
IN 4 Proximity 1 wheel speed ON_metal in front of proximity 1
IN 5 Thermo-switch series heating elements ON = series closed (OK),
OFF= series open (alarm)
IN 6 External start button ON = button pushed
IN 7 External start button ON = button non pushed

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Due to the lack of space, the last 4 indices have been omitted on this page, the polarity appears
directly.
By pushing the buttons or it is possible to view the other diagnostic pages:
Analogue data page
Page of the temperatures
On this page, the parameters have the following meaning:
IN 8 Micro-switch protective guard ON = protective guard open,
OFF= protective guard closed
IN 9 Proximity presence hopper ON = proximity turned on (hopper present)
IN 10 Photocell presence material/hopper full ON = material in front of photocell
IN 11 == ==
IN 12 Proximity position at the bottom of the
sealer
ON = metal in front of proximity
IN 13 Proximity 2 wheel speed ON = metal in front of proximity 2
IN 14 Micro-switch looop ON = top loop (==>tensioned material, deduct the
correction loop from the velocity of M3)
IN 15 Front sensor presence cushion ON = interrupted beam=cushion too far forward ==>add
the correction of the velocity of M3
IN 16 == ==
Parameter Description
IN The reading and the internal temperature value of the machine (in decimals of °C)
ENV The reading and the ambient temperature value (in decimals of °C) if the sensor is
present, otherwise "NO RX" is shown
TT The reading and temperature of the cross sealer (in decimals of °C)
TL1 The reading and temperature of the lower longitudinal sealer (in decimals of °C)
TL2 The reading and temperature of the upper longitudinal sealer (in decimals of °C)
Index Signal/function Polarity

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Operational page of the PID of sealer temperature (first temperature series)
Operational page of the PID of sealer temperature (second temperature series)
Compensation of the ambient temperature
Calibration data
Jog page: It is possible operate on this page only with machine in standby.
With the buttons and select engine/device to activate, press for activation.
From this page is possible to make following actions:
•M1forward
• M1 backward
• Reset M1

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•M2forward
• M2 backward
•M3forward
•M4forward
• M5 ON (extraction fan)
• R1 ON (cross heating element)
• R2 ON (longitudinal heating element)
• Display of frequency, amount and temperatures
5 MACHINE PARAMETERS PAGE
This is accessed by pushing and .
Here, all the parameters are assembled which remain operational for all formulas.
In order to move between pages, push the buttons or , to move between parameters/actions
push and ; to change a parameter push ; to exit from these pages, push .
The parameters are:
The screen shots are shown as follows:
Page Parameter Unit Function
1/2 Min.P.Save Minutes Time to go into power safe
1/2 Min.Standby Minutes Time to go into standby
1/2 N.Photo 0/1/2 Number of photocell basket. The value changes by pushing ENTER
1/2 S.Ant.Asp. Seconds Seconds of ignition timing of the extraction fan at the beginning:
at the start (if the extraction fan has not yet turned on due to the
subsequent parameter) the extraction fan is turned on and waiting to
start running for that time
1/2 Min.Del.Asp Minutes Seconds of delayed turning off of the extraction fan at the stop
1/2 S.Start Pht Seconds Delay at the start of the photocell head
1/2 S.Stop Pht Seconds Delay at the stop of the photocell head
2/2 En. butt. 0/1 Enabling external start/stop input

9
6 PAGES FOR PARAMETER SETTINGS
Turn on by pushing and ; the parameters that differentiate the 9 formatting recipes are listed on
these pages and may be modified;
There are two pages for each format; the first line shows the index (1-9) of the programme and the page (1/2
or 2/2)
On the first screen
And on the second screen.
Here, one can move through the pages with the buttons or ,
within the page with buttons and ; the value of a parameter is changed using the button .
Exit from these pages using the button .

10
The following settings for parameters are shown:
7 PAGES FOR SELECTING OPERATIONAL SETTINGS
These pages describe the characteristic parameters of the operating programmes (a total of nine of which six
have already been pre-programmed).
To access these pages, push the buttons and . with buttons or .
Here, one can move between the nine programmes available, for which the name and index are shown
(highlighted for the programme in operation); use the button to start the selected programme, use this
button to exit.
8ALARMS
Page Parameter Unit Description
Page 1/2 Name Alphanumeric Name of the setting
% Spd.M1 % (1-100) Max. velocity of sealer
% Spd.M2 % (1-100) Max. velocity of transporting film
% Spd.M3 % (1-100) Max. velocity of transporting airpads
% Spd.M4 % (1-100) Max. velocity of vent
°C Trasv. °C Operating temperature of cross sealer
C Long. °C Operating temperature of longitudinal sealer
Page 2/2 mm Pad mm Length of airpads
n.Pads N Number of airpads in one chain
ms Weld. ms Time for sealing: if it is different from 0,
the sealer stops sealing after this time.
Label Cause Possible measures
E1 Thermo-switch series on
heating elements open
• Temperature of one or more heaters not controlled, allow
machine to cool off
• Check connection/thermo-switch
E2 Temperature alarm
cross sealer
• The temperature of the cross sealer does not reach the desired
temperature within the programmed time with the parameter
"Min.All.Temp", check the connection of the sealer and the
corresponding thermocouple
• Check the PID parameters
E3 Temperature alarm
longitudinal sealer
• The temperature of the longitudinal sealer does not reach the
desired temperature within the programmed time with the
parameter "Min.All.Temp", check the connection of the sealer
and the corresponding thermocouple
• Check the PID parameters

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E4 Protective guard alarm • Micro-switch of the front protective guard is open, close the
carter
• Check connection
E7 Encoder sealer M1 • The encoder of sealer M1 is not counting, check that the sealer
is not blocked mechanically
• Check the micro-switch of the protective guard
• Check connection
E8 Encoder feeder M2 • The encoder of feeder M2 is not counting, check that the sealer
is not blocked mechanically
• Check connection
E9 Jam sensor • Airpads jammed, check the operating and machine parameters
• Check the distance of the sensors relative to the light spot
• Check connection
E10 Zeroing sensor
Sealer M1 not found
• The zero sensor of the sealer did not turn on,
check the position and connection
E11 Temperature of the cross
sealer not within normal
range
• Check the connection of the thermocouple of the cross sealer
• Make sure that all the thermocouples are insulated
E12 Temperature of one of
the longitudinal sealers
not within normal range
• Check the connection of the thermocouple of the longitudinal
sealers
• Make sure that all the thermocouples are insulated
E13 The temperature of the
cross sealer does not
increase when heated
• Check the connection of the thermocouple of the heating
element of the cross sealer
E14 The temperature of one
of the longitudinal
sealers does not
increase when heated
• Check the connections of the thermocouples of the heating
elements of the longitudinal sealers
Label Cause Possible measures