Omni Cresco User manual

Omni Cresco

INDEX
1 OPERATORS...................................................................................................................5
2 CONTROL PANEL...........................................................................................................6
3 DISPLAY........................................................................................................................11
4 GENERAL PARAMETERS............................................................................................12
5 PARAMETERS DESCRIPTIONS...................................................................................13
6 TURNING ON.................................................................................................................18
7 LOADING AND UNLOADING........................................................................................19
8 PAUSE ...........................................................................................................................19
9 RESET............................................................................................................................20
10 RESTARTING AFTER AN EMERGENCY STOP.........................................................20
11 SETTING THE PARAMETER VALUE CYCLE ............................................................21
12 OPERATING IN AUTOMATIC MODE – STANDARD WRAPPING CYCLES..............21
13 CUSTOMIZED CYCLE.................................................................................................24
14 CREATION OF A CUSTOMIZED CYCLE....................................................................24
15 USE OF A CUSTOMIZED CYCLE...............................................................................25
16 MANUAL MODE...........................................................................................................25
17 “PLAY BACK” CYCLE ................................................................................................25
18 CREATION OF A “PLAY BACK” CYCLE...................................................................26
19 USING A “PLAY BACK” CYCLE ................................................................................28
20 FORMATTING SAVED DATA......................................................................................29
21 LOCKING AND UNLOCKING THE BUTTONS ...........................................................30
22 ALARMS ......................................................................................................................30
23 DIAGNOSTIC ...............................................................................................................32
24 STANDARD FILM ROLL CARRIAGE..........................................................................33
25 POWER PRE-STRETCH CARRIAGE..........................................................................36
With a view to continuous improvement of this machine’s functions, some of its components and/or
characteristics could be modified without notice and without prejudice to the validity of this
document. If differences are found between the contents of this manual and the actual machine
operation, please communicate them to the builder.
CRESCO UCP REV10 3

1 OPERATORS
The machine was designed to be used even by just one operator. Operators must:
-have understood the contents of this manual;
-be aware of the main accident prevention norms;
-know how to react in case of emergency;
-be provided with the necessary personal protective equipment and know how to use it properly.
Qualified maintenance technicians, as well as possessing the listed characteristics, must be
adequately trained in the mechanic and electrical sector.
CRESCO UCP REV10 5

2 CONTROL PANEL
The machine controls are set on a control panel located in the column, in a position easily
accessible to the operator.
The control panel position allows control devices to be located:
-away from dangerous areas of the machine;
-away from the work area of the machine;
-near emergency stop devices.
CRESCO UCP REV10 6

The control devices are divided into:
-mechanical actuators (buttons);
-information devices.
DISPLAY
LED
WARNING
LIGHT
JOG +
JOG -
AUTOMATIC
MANUAL / OK
RESET
START
STOP
CYCLE
SELECTION
CYCLE
WARNING
LIGHTS
BOTTOM
WRAPPING
ADJUSTMENT
FILM TENSION
ADJUSTMENT
MANUAL CONTROL
AND TABLE
ROTATION SETTING
TOP
WRAPPING
ADJUSTMENT
MANUAL CONTROL
AND CARRIAGE
ASCENT SETTING
MANUAL CONTROL
AND CARRIAGE
DESCENT SETTING
SAVE
LOAD
RECORD
EMERGENCY STOP
BUTTON
MASTER SWITCH
CRESCO UCP REV10 7

Please find below a short description of the function of every button and indicator located on the
control panel.
BUTTON-INDICATOR DESCRIPTION FUNCTION
MAIN SWITCH
It turns the machine on and off. When it is in
the 1 position the machine is on.
NEVER USE THE MAIN SWITCH TO STOP
THE MACHINE DURING A WRAPPING
CYCLE.
DISPLAY
When the machine is being turned on, the
display shows the software version of the
control logic.
It show
s the current value of the individual
parameters selected and the values set by the
user with the JOG+ and JOG- buttons.
EMERGENCY
STOP BUTTON
When pressed, all m
oving parts of the
machine are stopped in the shortest possible
time. To be used in case dangerous or alarm
conditions arise.
JOG +
To be used to increase the value of the
selected parameter.
JOG -
To be used to decrease the value of the
selected parameter.
AUTOMATIC /
MANUAL SWITCH
OK
To be used to choose to work in AUTOMATIC
or MANUAL mode.
Also used to confirm the
selected value.
CYCLE
SELECTION
ESC
When the machine is in AUTOMATIC mode,
this button
is used to select the cycle to
perform. Also used to quit the current menu.
START
When the machine is in AUTOMATIC mode,
this button starts the selected wrapping cycle
or restarts it from the point where it was
stopped.
When the machine is in PROGRAMMING
mode (RECORD…),
it select the way of
st
arting for the PLAY BACK cycle (see Play
Back section for more informations)
CRESCO UCP REV10 8

START (LED)
If lit, it indicates that the machine is performing
a wrapping cycle
or the that the machine is
waiting for the START to begin a Play Back
cycle.
If flashing, it i
ndicates that the machine is on
pause waiting for the Start to restart the
paused cycle.
STOP
When the machine is in AUTOMATIC mode, if
pressed, the button stops the wrapping cycle,
even if it has not finished yet (pause).
When the machine is in progra
mming mode
(RECORD), if pressed, the button memorizes
the machine stop in the cycle
that is being
saved.
STOP (LED)
When the machine I in AUTOMATIC mode, if
the STOP button is pressed, the led flashes
together with the START led.
When the machine is in
programming mode
(RECORD), it has different configurations
depending on the operating process (see Play
Back section for further informations)
RESET
When pressed, it reinitialises the machine
during turning on and after an emergency
stop.
During loading and save phases this button
cancels the operations performed.
RESET (LED)
If lit, it indicates that a RESET cycle is being
performed.
If flashing, it signals the need to perform a
reset cycle.
SAVE
Press SAVE to save a data set or a
customized cy
cle (“play back” cycle) and
associate an identification.
LOAD
Press LOAD to recall and load a data set or a
customized cycle (“play back” cycle).
The load menu begins with custom cycles
(Pr1-Pr9) and continues with Play Back cycles
(rEc1-rEc9).
CRESCO UCP REV10 9

RECORD
Press RECORD to enter in programming
mode.
ASCENT-
DESCENT CYCLE
(LED)
If lit (and when the machine is in AUTOMATIC
mode), it indicates that the ASCENT
DESCENT wrapping cycle has been selected.
ASCENT ONLY
CYCLE
(LED)
If lit (and when the machine is in AUTOMATIC
mode), it indicates that the ASCENT ONLY
wrapping cycle has been selected.
TOP SHEET
CYCLE
(LED)
If lit (and when the machine is in AUTOMATIC
mode), it indicates that the TOP SHEET
wrapping cycle has been selected.
P-01 – P06 CYCLE
If they are all off (in MANUAL mode) it means
that the machine is in manual function.
If they all flash it means that a Play Back cycle
is being registered.
BOTTOM
WRAPPING
ADJUSTMENT
(BUTTON AND
LED)
When selected (LED light on) in AUTOMATIC
mode, the value set for BOTTOM WRAPPING
appears on the display (C1).
The value can be changed using
the JOG +
and JOG - buttons.
TOP WRAPPING
ADJUSTMENT
(BUTTON AND
LED)
When selected (LED light on)
in automatic
MODE
, the value set for TOP WRAPPING
appears on the display (C2).
The value can be changed using
the JOG +
and JOG - buttons.
FILM TENSION
ADJUSTMENT
(BUTTON AND
LED)
When selected (LED light on), the value set
for FILM TENSION (percentage) appears on
the display.
The value can be changed using t
he JOG +
and JOG - buttons.
CRESCO UCP REV10 10

TABLE ROTATION
(BUTTON AND
LED)
When the machine is in MANUAL mode, this
button starts and stops table rotation.
When selected (in AUTOMATIC or MANUAL
mode - led light on), the table rotation speed
(RPM) appears on the display. The speed can
be changed using the JOG + and JOG -
buttons.
CARRIAGE
ASCENT
(BUTTON AND
LED)
When the machine is in MANUAL mode, this
button starts and stops the carriage ascent.
When selected (in AUTOMATIC or MANUAL
mode - led light on), the carriag
e ascent
speed (Hz) appears on the display. The speed
can be changed using the JOG + and JOG -
buttons.
CARRIAGE
DESCENT
(BUTTON AND
LED)
When the machine is in MANUAL mode, this
button starts and stops the carriage descent.
When selected (in AUTOMATIC
or MANUAL
mode -
led light on), the carriage descent
speed (Hz) appears on the display. The speed
can be changed using the JOG + and JOG -
buttons.
3 DISPLAY
The machine’s control panel is equipped with a display showing alarms and parameter settings.
To scroll up and down the menus and set parameter values, use the JOG + and JOG - buttons.
Press AUT-MAN-OK to select the menu to be displayed and to enter the following display / setting
level, or to confirm a set value.
Press PRG-ESC to exit a menu or parameter, to go back to a previous level, or to cancel an
inserted value.
CRESCO UCP REV10 11

4 GENERAL PARAMETERS
If necessary, users can change the settings of the machine general parameters.
The builder suggests that register values are not changed if not strictly necessary, as
accidental changes may lead to machine malfunctions.
ATTENTION: GENERAL PARAMETERS MUST ONLY BE CHANGED BY EXPERIENCED
STAFF, WITH A DEEP KNOWLEDGE OF THE MACHINE AND OF THE PARAMETERS
MEANING.
Turn the main switch to power up the machine.
As soon as the software version appears on the control panel
display, press the buttons START and AUT-MAN at the same time.
Use JOG + and JOG - to scroll the parameters list and choose the
one to be changed.
CRESCO UCP REV10 12

Press AUT-MAN to access the parameter.
Use JOG + and JOG - to set the parameter value.
Press AUT-MAN to save the new set value.
5 PARAMETERS DESCRIPTIONS
N = Standard
M = Motus
TP = Cresco TP
NAME CYCLE PARAMETERS DESCRIPTION
MIN
MAX
DEF
N
M
N
M
N
M
C1
Low Revolutions
Number of revolutions of the
table, when the wrapping
machine is wrapping the lower
part of the object, requiring
packing (listed).
0 0 10 10 1 1
C2
High Revolutions
Number of revolutions of the
table, when the wrapping
machine is wrapping the upper
part of the object, requiring
packing, after completion of
the “Overflow Delay”. (listed)
0 0 10 10 1 1
C3
Stretch
Film tension during the
playback of a cycle 0 0 100 100 50 50
C4
Rpm Rotation
Standard table rotation speed.
(RPM) 1 1 13 8 11 7
C5
Ascent Speed
Carriage speed in the ascent
stage (Hz) 15 15 80 80 65 50
C6
Descent Speed
Carriage speed in the descent
stage (Hz)
15 15 80 80 65 50
CRESCO UCP REV10 13

NAME GENERAL PARAMETERS DESCRIPTION MIN MAX DEF
N
M
N
M
N
M
TP
G1 Rotation Speed
Rotation speed of the
table in the MANUAL
mode and during the
memorization of a
Play Back cycle.
(RPM)
1 1 13 8 10 7 10
G2 Speed Up
Ascent speed of the
carriage in the
MANUAL mode and
during the
memorization of a
Play Back cycle. (Hz)
15 15 80 80 50 50 50
G3 Speed Down
Descent speed of the
carriage in the
MANUAL mode and
during the
memorization of a
Play Back cycle. (Hz)
15 15 80 80 50 50 50
G4 Manual Stretch
Film tension during
the MANUAL mode
and during the
playback of the Play
Back cycle
0 0 100 100 20 20 20
G5
Rmp To Hz
Conversion
Rpm to Hz
Conversion 0 0 5000 5000 2000 3173 2400
G6 Cm To Point
Carriage
Conversion of the
revolutions of the
magnetic field in cm 0 0 5000 5000 1300 542 1300
G7 Table Net Cycles
One Revolution
Information used to
know how many
revolutions of the
magnetic field are
required to complete
an entire revolution of
the table
10 10 1000 1000 305 194 254
G8 Reset 1 Position
During braking, the
position of the table
(in %), in which the
first slowdown is
carried out
30 30 100 100 70 70 50
G9 Reset 2 Position
During braking, the
position of the table
(in %), in which the
second slowdown is
carried out
30 30 100 100 85 85 90
CRESCO UCP REV10 14

G10 Extra Length Delay
Waiting time, from
when the photocell no
longer detects the
pallet to when the
carriage stops. (sec)
0.0 0.0 10.0 10.0 1.0 1.0 1.0
G11 Brake Calibration
Value in percentage
corresponding to
100% of the braking.
This value sets the
maximum percentage,
to which the
percentages of the
other film tension
parameters refer to.
(in %)
0 0 100 100 15 10 15
G12 Film Tension Start
Film tension, when a
cycle is started and
upon restart from the
pause of the Stretch
Sheet cycle. (in %)
0 0 100 100 10 10 10
G13 Start Delay Time
Waiting time, from
when the parameter
“Start Film Tension” is
enabled to when the
cycle parameter
“Stretch” (in sec) is
automatically enabled.
0.0 0.0 10.0 10.0 5,0 5,0 5,0
G14 Last Revolution
Tension
Film tension during
the table braking
stage. (in %) 0 0 100 100 15 15 15
G15 Tension Pause
Film tension when the
machine is in the
AUTOMATIC mode
and is not performing
any cycle.
0 0 100 100 0 0 0
G16 Descent Time
Descent Time, from
when the carriage
arrives at the end of
the pallet (for the first
time) to then go down
for this amount of
time. (in sec).
Used only in the
“Stretch Sheet cycle”
0.0 0.0 10.0 10.0 3,0 3,0 3,0
G17 Reset Speed
Table rotation speed
of the table during the
stage, in which the
table places itself on
zero. (RPM)
1 1 10 10 5 5 5
CRESCO UCP REV10 15

G18 Pallet Height
Height end of cycle
start (cm) 0 0 200 200 0 0 0
G19 YoYo Height
YoYo Height
0 0 200 200 0 15 0
G20 Pallet control
enabling
If = ON : during the
cycle, the sensor loses
the Pallet, an error is
generated
0 0 1 1 0 1 0
G21 Machine Code
0 = machine normal
1 = it has only one limit
switch for high and for
low
2 = Motus Version
0 0 2 2 0 2 0
TABLE MOTOR PARAMETERS
NAME
DESCRIPTION
MIN
MAX
DEF
N
M
N
M
N
M
TP
H1
Chopper frequence :
1=1khz ... 20=20khz 1 1 20 20 4 4 4
H2
Maximum current from dc bus:
10=1A … 100 = 10A 10 10 100 100 40 40 40
H3
Overtemperature threshold :
30=30°C … 100=100°C
30 30 100 100 80 80 80
H4
Minimum voltage dc bus:
5 = 50V … 32=320V 0 0 32 32 25 25 25
H5
Maximum voltage dc bus:
16 = 160V … 50=500V
16 16 50 80 40 40 40
H6
Start voltage reduction low
speed (boost):
10=10hz … 80= 80hz 10 10 80 80 50 50 50
H7
voltage at 0 Hz (boost): 0 = 0%
… 40 = 40% 0 0 40 40 15 15 15
H8
Acceleration:
1=1dsec (0,1sec) …
100=100dsec (10sec)
1 1 100 100 25 25 25
H9
Deceleration:
1=1dsec (0,1sec) …
100=100dsec (10sec)
1 1 100 100 20 20 15
H10
Braking duration cc:
1=1dsec (0,1sec) …
100=100dsec (10sec) 0 0 100 100 10 10 10
H11
Braking intensity cc:
1=1% … 100=100% 0 0 100 100 10 10 10
H12
Speed inversion control , 0=std ,
1=reversed 0 0 1 1 0 0 0
CRESCO UCP REV10 16

H13 I2T "thermal" (°C) 5 5 100 100 25 25 25
H14
Braking intensity cc from a
standing position: 1=1% …
100=100% 0 0 100 100 15 15 15
PARAMETERS CARRIAGE MOTOR
NAME
DESCRIPTION
MIN
MAX
DEF
N
M
N
M
N
M
U1
Chopper frequence :
1=1khz ... 20=20khz 1 1 20 20 4 4
U2
Maximum current from dc bus:
10=1A … 100 = 10A
10 10 100 100 40 40
U3
Overtemperature threshold :
30=30°C … 100=100°C 30 30 100 100 80 80
U4
Minimum voltage dc bus:
5 = 50V … 32=320V 0 0 32 32 25 25
U5
Maximum voltage dc bus:
16 = 160V … 50=500V 16 16 50 50 40 40
U6
Start voltage reduction low
speed (boost):
10=10hz … 80= 80hz
10 10 80 80 50 50
U7
voltage at 0 Hz (boost): 0 = 0%
… 40 = 40% 0 0 40 40 15 15
U8
Acceleration:
1=1dsec (0,1sec) …
100=100dsec (10sec) 1 1 100 100 5 5
U9
Deceleration:
1=1dsec (0,1sec) …
100=100dsec (10sec)
1 1 100 100 2 2
U10
Braking duration cc:
1=1dsec (0,1sec) …
100=100dsec (10sec)
1 1 100 100 10 10
U11
Braking intensity cc:
1=1% … 100=100% 1 1 100 100 10 10
U12
Speed inversion control , 0=std ,
1=reversed 0 0 1 1 0 0
U13
I2T "thermal" (°C)
5
5
100
100
25
25
U14
Braking intensity cc from a
standing position: 1=1% …
100=100% 0 0 100 100 15 15
CRESCO UCP REV10 17

6 TURNING ON
If the control panel is off, press the ON/OFF switch to power it up, then wait a few moments.
The number of the software version The number of the software version of the type of wrapping
machine (which can be modified by G21), and then, the value of the number of pallets completed
(from the last reset of the memory) will be displayed for a few seconds.
The RESET led flashes.
Press RESET to start the machine. Wait for the end of the reset cycle and the end of the acoustic
signal to begin using the machine.
When the RESET button is pressed, an acoustic signal is emitted. The rotating table and the
carriage reach their zero positions.
Once the RESET cycle has finished, the machine will have the same settings it had before it was
last shut down. The machine has been programmed to carry out different wrapping cycles. The
operator shall select the cycle which corresponds best to the characteristics of the load to be
wrapped. Select the cycle type to be carried out and set the parameter values according to the
specific needs.
CRESCO UCP REV10 18

7 LOADING AND UNLOADING
Place the load to be wrapped on the rotating table in the correct way, and check its stability. Fix the
film end to the pallet.
The load must be well balanced to avoid
risks.
At the end of the wrapping cycle, cut the film,
unload the wrapped product and load a new
pallet. If the
machine is not in the correct
position when it stops, press the RESET button
and it will go back to its initial position.
8 PAUSE
During each wrapping cycle, except for the ones in the MANUAL working mode:
- press STOP to stop the cycle; the START and STOP leds flash.
- press START to restart the cycle from the point where it was
stopped.
- If you wish to exit the cycle during the Pause mode, it is
necessary to press Stop again and an acoustic signal is emitted.
Accordingly, the Reset will be required.
CRESCO UCP REV10 19

9 RESET
During each wrapping cycle, except for the ones in the MANUAL working mode:
- press RESET to bring the machine to its zero position.
This assures that the cycle operations performed are deleted.
- During this stage, if the RESET switch is pressed again, the
wrapping machine stops and the zero point is set and it is
possible to start the following cycle. A prolonged acoustic signal
is emitted, as in the case of the cycle end.
10 RESTARTING AFTER AN EMERGENCY STOP
Shall it be strictly re
quired to stop the machine, press the
emergency mushroom stop button located in the control panel
(RED button on yellow background). The machine will safely stop
in the shortest possible time.
After pressing the emergency stop button, act in the following way:
- reset the emergency stop button;
- press the RESET button to restore the machine.
When the RESET button is pressed again, the machine reaches its zero position. Once the
repositioning has finished, an acoustic signal is emitted, as at the cycle end.
Press the START button to continue the cycle being carried out before the emergency stop. By
pressing only the START button after the emergency button has been reset, the machine cannot
be restarted.
CRESCO UCP REV10 20

Before restoring the machine after an emergency stop, make sure that the danger situation
has been appropriately eliminated.
11 SETTING THE PARAMETER VALUE CYCLE
To change the value of a parameter, act in the following way:
Select the parameter to be set. When a parameter has been selected, the led that identifies it is lit
and the value of the parameter is displayed (flashing).
Set the value of a parameter selected with the JOG + and JOG – buttons. The changed value is
immediately memorized. Thus, if a cycle is being carried out, the change is performed in real time
(except for Low Revolutions and High Revolutions, which during their performance, are not
modified in real time).
To save a configuration, which must be used several times, then consult the paragraph
“CUSTOMIZED CYCLE”.
12 OPERATING IN AUTOMATIC MODE – STANDARD WRAPPING CYCLES
The machine has been programmed to carry out three different standard wrapping cycles. The
operator shall select the cycle which corresponds best to the characteristics of the load to be
wrapped. Select the cycle type to be carried out and set the parameter values according to the
specific needs.
Repeatedly press the PRG
button (with the machine in
AUT) to select the wrapping
cycle to be performed.
CRESCO UCP REV10 21

Press START to start the selected wrapping cycle.
The available cycles are illustrated here below.
At the end of the wrapping cycle the machine automatically stops in the unload position of the
product. When the machine is working in the standard mode, the cycle should not be manually
stopped. Press the STOP button only if you need to stop the cycle for a particular reason. The
cycle will be suspended. When the START button is pressed, the cycle will start again from the
same position when it was interrupted and it will be completed.
ASCENT AND DESCENT CYCLE
The pallet is wrapped while the carriage moves up and
down.
At the end of the wrapping cycle the machine automatically stops in the unload position of the
product. When the machine is working in the standard mode, the cycle should not be manually
stopped. Press the STOP button only if you need to stop the cycle for a particular reason. The
cycle will be suspended. When the START button is pressed, the cycle will start again from the
same position when it was interrupted and it will be completed.
DETAILED DESCRIPTION
Press START to start up the automatic wrapping cycle.
The wrapping machine performs the following steps:
a) The table starts to rotate at the speed (C4), the film tension start is set (G12) and the delay
start time (G13) is clocked, after which the film tension is set with the stretch value (C3).
b) Once the low revolutions end (C1), the carriage goes up at the speed (C5)
c) From when the pallet is no longer found, the extra length time is clocked (G10)
d) After t
he time has elapsed, the carriage stops and waits for the completion of the high
revolutions (C2)
e) The carriage goes down at the speed (C6)
f)
Once it arrives at the limit switch height, the machine automatically looks for the zero
position. The speed set in this last revolution and the reset one (G17) as well as the tension
of the film is set as tension of the last revolution (G14)
g) At the end of the wrapping cycle the machine automatically stops in the unload position of
the product.
CRESCO UCP REV10 22