master_cut.txt

Alarm Testing

Important Information



The following table lists the fault messages, warning messages and messages which are displayed on the
control panel but can be simulated only by program changes and are therefore not tested.





WARNING



	To perform a test procedure, it may be necessary to start the 	machine 	while the doors are open and the door contact switches are
	bridged.

	Safety functions are non-activ.

	Severe injuries may result.

	►	Only authorized/trained persons are allowed to run the machine.

	►	Special attention must be given and care taken when working in
		the danger zone without protection.



Please note that some fault messages, warnings or messages may contain a variable which is

generated e.g. from the servo drive or profibus and gives further information about this device. The variable depends on the actual fault and therefore may vary.



Message number

Message text

ME 0162

MOTION CONTROL: DATA TRANSMISSION TO MOTION DRIVES



Warning number

Warning text

WA 0015

CONTROL-PC: USED DISK SPACES EXCEEDS 80 %

WA 1024

HARD DRIVE CAPACITY 80%



Fault number

Fault text

FLT 0008 

HMI: FAULT COMMUNICATION TO CONTROL

FLT 0012 

MOTION CONTROLLER: -400: COMMUNICATION ERROR

FLT 0013 

MACHINE: REFERENCE NOT SET TO ZERO

FLT 0015 

CONTROL PC:USED DISK SPACE EXCEEDS 90%

FLT 0070

FAULT ABSOLUTE TRANSMITTER SUN WHEEL ROTOR

FLT 0462 

TLT: SERIAL COMMUNICATION ERROR

FLT 0733

FAULT SYNCHRONIZATION TRANSFER UNIT

FLT 1024

HARD DRIVE CAPACITY 90%







Test protocols - Faults (FLT)

FLT 3: OPERATOR: NORMAL STOP ACTUATED



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Press “Stop”



Consequence

Fault message is displayed on control panel



Comments

None



Acknowledgement

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x

Comments

	

x

x



















Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	

FLT 4: OPERATOR: WRONG OPERATING MODE SELECTED



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in setup mode



Required operations

Activate SWS 4 “Inching cable“



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Activate SWS 2 “Setup”

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x













Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 5: COMPRESSED AIR: MONITORING INLET PRESSURE



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is running



Required operations

Close the compressed air supply



Consequence

Machine stops

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

Caution: defective leaflet and carton conveyance possible



Acknowledgement

Open the compressed air supply

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Machine stops

	

x

x



Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x







Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 6: ETHERCAT: FAULT + VARIABLE



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode

Guard doors are bridged



Required operations

Press “Start”

Disconnect ethernet plug



Consequence

Machine stops

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

Observe without fail! Control Cabinet door is open!

Additionally other fault messages are displayed on control panel

The variable contains further information about ethercat connection



Acknowledgement

Reconnect ethernet plug

Press “Reset”








Test result

	

	yes/no

Acceptance Criteria

Machine stops

	

x

x



Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x









































Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	

FLT 7: COMPRESSED AIR: MONITORING SAFE SHUTDOWN



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Disconnect "=CAR1.Q95-Q01“



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Reconnect "=CAR1.Q95-Q01“





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x















Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 9: FAULT PROFIBUS + VARIABLE



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Press “Start”

Disconnect profibus plug



Consequence

Machine stops

Fault message is displayed on control panel

Machine cannot be started as long as fault is active

Further fault messages (“variable”) are displayed



Comments

Observe without fail! Control Cabinet door is open!

Additionally other fault messages are displayed on control panel



Acknowledgement

Reconnect profibus plug

Press “Reset”



Test result

	

	yes/no

Acceptance Criteria

Machine stops

	

x

x



Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x



Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	

FLT 11: MOTION DRIVES: OVERLOAD POWER SUPPLY



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Disconnect input "=CAR1.K00-KI04:10“



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Reconnect input





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x















Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 16: HANDWHEEL IS ENGAGED



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in setup mode



Required operations

Pull out the hand wheel



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Pull in the hand wheel

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x













Results comply

	

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

	

x

xDate/Initials

	




FLT 17: OPERATOR: OPERATING MODE CHANGE



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode 



Required operations

Change over to setup mode



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x















Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 20: BATCH CONTROL: PARTIAL BATCH OBTAINED



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Partial batch is defined and started

Machine is ready in automatic mode



Required operations

Press “Start”



Consequence

Machine runs until the defined quantity of good products of the partial batch is obtained

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Machine runs until the defined quantity of good products of the partial batch is obtained

	

x

x



Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x





Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	

FLT 21: BATCH CONTROL: COMPLETE BATCH OBTAINED



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Complete batch is defined and started

Machine is ready in automatic mode



Required operations

Press “Start”

Machine runs until it reaches the batch size



Consequence

Machine stops when the defined quantity of good products of the batch size is obtained

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Machine stops when the defined quantity of good products of the batch size is obtained

	

x

x



Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x



Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 22: VACUUM: OVERLOAD PUMP



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Switch off protective motor switch “=CAR1.G05-Q10“



Consequence

Machine stops

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Switch on protective motor switch “=CAR1.G05-Q10“

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Machine stops

	

x

x



Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x







Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 23: VACUUM: MONITORING NEGATIVE PRESSURE



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is running in automatic mode



Required operations

Activate SWS 54 “Machine vacuum”

Disconnect sensor “=CAR1.G05-B80“



Consequence

Machine stops

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Reconnect sensor “=CAR1.G05-B80“

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Machine stops

	

x

x



Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x





Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 26: CONTROL CABINET: FAULT SAFETY PLC



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Disconnect input ".K00-KIS01:7“ (One plug of emergency stop)



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x















Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 30: MACHINE: WAS RACED BACKWARDS



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Turn handwheel backwards



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x















Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 35: CONTROL CABINET: MONITORING MAIN SWITCH



Test objective

Test whether correct fault message is displayed on control panel





Test procedure



Test prerequisites

Machine is ready in automatic mode 



Required operations

Switch off main switch and switch on immediately



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x















Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	

FLT 41: CONTROL CABINET LEFT: OVERTEMPERATURE



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode 



Required operations

Adjust value of temperature controller (Control cabinet left) “=CAR1.W00-B11" less than the actual temperature in the control cabinet



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Set temperature controller “=CAR1.W00-B11" back to previous value of 45 °C

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x







Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 42: CONTROL CABINET RIGHT: OVERTEMPERATURE



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Adjust value of temperature controller (Control cabinet right) “=CAR1.W00-B13" less than the actual temperature in the control cabinet

Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Set temperature controller “=CAR1.W00-B13" back to previous value of 45 °C

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x









Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 43: CONTROL CABINET: VOLTAGE MONITORING



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Switch off fuse “=CAR1.W00-F3053”



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Switch on fuse “=CAR1.W00-F3053”

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x













Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 78: EMERGENCY STOP: SAFETY RELAY NOT ACTIVE



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Disconnect input “91K20“ Pin A1



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Reconnect input “91K20“ Pin A1

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x













Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 79: LINE EMERGENCY STOP ACTUATED



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Line is running at reduced speed



Required operations

Press “EMERGENCY STOP” strike button of rontech turret magazine



Consequence

Line stops

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Unlock “EMERGENCY STOP” strike button of rontech turret magazine

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Line stops

	

x

x



Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x







Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 81: EMERGENCY STOP ACTUATED: OPERATING PANEL



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is running with reduced speed



Required operations

Press “EMERGENCY STOP” strike button



Consequence

Machine stops

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Unlock “EMERGENCY STOP” strike button

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Machine stops

	

x

x



Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x







Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 83: GUARD BASIC MACHINE: SAFETY RELAY NOT ACTIVE



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Disconnect input “=CAR1.F91-K01“ Pin ”A1“



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Reconnect input “=CAR1.F91-K01“ Pin ”A1“

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x













Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	



FLT 86: GUARD OPEN: BOTTOM



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Open guard door bottom



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Close guard door bottom





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x















Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 86: GUARD 8 OPEN



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Open guard door 8



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Close guard door 8





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x















Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 87: GUARD OPEN: CARTON BELT



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Open guard door front carton belt



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

Test can only be performed at standstill, because guard is locked while running



Acknowledgement

Close guard door front carton belt

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x











Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 87: GUARD 7 OPEN



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Open guard door 7



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

Test can only be performed at standstill, because guard is locked while running



Acknowledgement

Close guard door 7

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x













Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	

FLT 88: GUARD OPEN: INSERTION REAR



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode

 

Required operations

Open guard door insertion rear



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Close guard door insertion rear

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel



	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x













Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 89: GUARD OPEN: DISCHARGE FRONT



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Open guard door discharge front 



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active 



Comments

Test can only be performed at standstill, because guard is locked while  running 



Acknowledgement

Close guard door discharge front

Press “Reset” 





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x













Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	

FLT 90: GUARD OPEN: CONTROL CABINET SWIVELED OFF LEFT



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode

 

Required operations

Open guard door control cabinet rear left 



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active 



Comments

Test can only be performed at standstill, because guard door is locked while running 



Acknowledgement

Close guard door control cabinet rear left

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x













Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	

FLT 91: GUARD OPEN: CONTROL CABINET SWIVELED OFF RIGHT



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode 



Required operations

Open guard door control cabinet rear right 



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active 



Comments

Test can only be performed at standstill, because guard door is locked while running 



Acknowledgement

Close guard door control cabinet rear right

Press “Reset” 





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x











Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	

FLT 96: GUARD OPEN: HANDWHEEL



Test objective

Test whether correct fault message is displayed on control panel





Test procedure



Test prerequisites

Machine is ready in automatic mode 



Required operations

Open guard door handwheel 



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active 



Comments

Test can only be performed at standstill, because guard is locked while running



Acknowledgement

Close guard door handwheel

Press “Reset” 





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x











Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 100: GUARD OPEN: PRODUCT CHAIN 1



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode 



Required operations

Open guard door product chain 1 



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active 



Comments

Test can only be performed at standstill, because guard is locked while running 



Acknowledgement

Close guard door product chain 1

Press “Reset” 





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x













Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	

FLT 100: GUARD 3 OPEN



Test objective

Test whether correct fault message is displayed on control panel





Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Open guard door 3 



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active 



Comments

Test can only be performed at standstill, because guard is locked while running 



Acknowledgement

Close guard door 3

Press “Reset” 





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x











Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 104: GUARD OPEN: INFEED



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode 



Required operations

Open guard door infeed front 



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active 



Comments

Test can only be performed at standstill, because guard is locked while running 



Acknowledgement

Close guard door infeed front

Press “Reset” 





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x













Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	

FLT 110: PRODUCT SENSING: CONSECUTIVE FAULT EXCESS HEIGHT



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode

Prepare three products which are too high

Product is available

 

Required operations

Counter 131 “Product: consecutive fault sensing excess height“ is set to 3

Press “Start” and call product

Press “Stop” in front of sensor “=CAR1.B10-B02”

Open guard door

Put the three products successively in front of “=CAR1.B10-B02”

Close guard door

Press “Reset”

Press “Start” 



Consequence

Machine stops

Fault message is displayed on control panel

Machine cannot be started as long as fault is active 



Comments

None



Acknowledgement

Remove the manipulated products

Press “Reset”








Test result

	

	yes/no

Acceptance Criteria

Machine stops

	

x

x



Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x









































Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	

FLT 111: PRODUCT SENSING: CONSECUTIVE FAULT



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode

Product is available



Required operations

Counter 112 “Product: consecutive fault sensing“ is set to 3

Press “Start” and call up product

Press “Stop” in front of sensor “10B1”

Open guard door

Remove 3x product from product chain successively in front of “10B1”

Close guard door

Press “Reset”

Press “Start”



Consequence

Machine stops

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Press “Reset”








Test result

	

	yes/no

Acceptance Criteria

Machine stops

	

x

x



Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x









































Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	

FLT 112: PRODUCT SENSING: SENSOR MONITORING



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Cover sensor ”=CAR1.B10-B01“ permanently

Press “Start”



Consequence

Machine stops

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Uncover sensor ”=CAR1.B10-B01“

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Machine stops

	

x

x



Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x





Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 113: PRODUCT SENSING: SENSOR MONITORING EXCESS HEIGHT



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Disconnect input “=.K00-KI08:14” and “=.K00-KI08:2”



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

Sensor ”=CAR1.B10-B02“ (Monitoring excess height) cannot be disconnected due to fix mechanical installation. Disconnection of the input simulates the wire break.



Acknowledgement

Reconnect inputs

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x









Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	

FLT 120: INSERTION: SAFETY SENSOR



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Disconnect sensor “=CAR1.B36-B01”

Press “Start” with product



Consequence

Machine stops

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Reconnect sensor “=CAR1.B36-B01”

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Machine stops

	

x

x



Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x





Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 121: INSERTION: DEFECTIVE PRODUCT STOPPED PLEASE REMOVE



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Prepare faulty product (e.g. wrong code leaflet, wrong code carton)

Place the wrong product in the leaflet stack or carton stack

Activate SWS 102 “Product: defective product stop at insertion”

Run machine with faulty product (e.g. wrong code carton)

Press “Start” with product



Consequence

Machine stops

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Deactivate SWS 102 “Product: defective product stop at insertion”

Remove faulty product

Press “Reset”






Test result

	

	yes/no

Acceptance Criteria

Machine stops

	

x

x



Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x









































Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	

FLT 123: INSERTION: OVERLOAD



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Open guard door at insertion

Simulate overload at sensor “=CAR1.W40-B01“ (pull guide)



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x













Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 124: GUARD OPEN: SLIDE IN



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode

 

Required operations

Open guard door slide in



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

Test can only be performed at standstill, because guard is locked while running



Acknowledgement

Close guard door slide in

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x













Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	

FLT 126: INSERTION: OVERLOAD PREINSERTION



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode

Good product is being produced



Required operations

Press “Stop”

Move one preinserter to the back position

Press “Start”



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Move the preinserter back to its original position

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x





Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 173: INSERTION: SLIDE IN 1 NOT IN POSITION



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Disconnect sensor “40B1“



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Reconnect sensor “40B1“

Activate SWS 6 “Release stop brake”

Activate SWS 2 “Insertion”

Move shaft forwards and backwards to activate sensor

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x





Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 174: INSERTION: SLIDE IN 2 NOT IN POSITION



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Disconnect sensor “40B2“



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Reconnect sensor “40B2“

Activate SWS 6 “Release stop brake”

Activate SWS 2 “Insertion”

Move shaft forwards and backwards to activate sensor

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x





Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 175: INSERTION: SLIDE IN 3 NOT IN POSITION



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Disconnect sensor “40B3“



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Reconnect sensor “40B3“

Activate SWS 6 “Release stop brake”

Activate SWS 2 “Insertion”

Move shaft forwards and backwards to activate sensor

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x





Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 176: INSERTION: SLIDE IN 4 NOT IN POSTION



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Disconnect sensor “40B4“



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Reconnect sensor “40B4“

Activate SWS 6 “Release stop brake”

Activate SWS 2 “Insertion”

Move shaft forwards and backwards to activate sensor

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel



	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x







Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	

FLT 177: INSERTION: SLIDE IN 5 NOT IN POSTION



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode 



Required operations

Disconnect sensor “40B5“ 



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active 



Comments

None



Acknowledgement

Reconnect sensor “40B5“

Activate SWS 6 “Release stop brake”

Activate SWS 2 “Insertion”

Move shaft forwards and backwards to activate sensor

Press “Reset” 





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x





Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 178: MOTION DRIVE SLIDE IN TABLE: FAULT 
FLT 179: MOTION DRIVE SLIDE IN TABLE + VARIABLE



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode 



Required operations

Disconnect pin 5 from plug X1 at motor control unit “40A1“ 



Consequence

Fault message is displayed on control panel “Motion drive slide in table: fault“

Fault message is displayed on control panel “Motion drive slide in table: 127: excess temperature motor warning“

Machine cannot be started as long as fault is active 



Comments

The variable contains further information about motion drive.

In combination with this fault the variable “127: excess temperature motor warning“ is displayed on control panel. In combination with other faults the variable can be different. 



Acknowledgement

Reconnect temperature sensor

Press “Reset” 








Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel “Motion drive slide in table: fault“

	

x

x



Fault message is displayed on control panel “Motion drive slide in table: 127: excess temperature motor warning“

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x







































Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	

FLT 186: MOTION DRIVE HORIZONTAL PRESINSERTION: FAULT
FLT 192: MOTION DRIVE HORIZONTAL PRESINSERTION + VARIABLE



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode 



Required operations

Disconnect pin 5 from plug X1 at motor control unit “40A3“ 



Consequence

Fault message is displayed on control panel “Motion drive horizontal preinsertion: fault“

Fault message is displayed on control panel “Motion drive horizontal preinsertion: 127: excess temperature motor warning“

Machine cannot be started as long as fault is active 



Comments

The variable contains further information about motion drive.

In combination with this fault the variable “127: excess temperature motor warning“ is displayed on control panel. In combination with other faults the variable can be different.



Acknowledgement

Reconnect temperature sensor

Press “Reset” 








Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel “Motion drive horizontal preinsertion: fault“

	

x

x



Fault message is displayed on control panel “Motion drive horizontal preinsertion: 127: excess temperature motor warning“

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x







































Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 187: MOTION DRIVE VERTICAL PREINSERTION: FAULT
FLT 193: MOTION DRIVE VERTICAL PREINSERTION + VARIABLE



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode

 

Required operations

Disconnect pin 5 from plug X1 at motor control unit “40A4“ 



Consequence

Fault message is displayed on control panel “Motion drive vertical preinsertion: fault“

Fault message is displayed on control panel “Motion drive vertical preinsertion: 127: excess temperature motor warning“

Machine cannot be started as long as fault is active 



Comments

The variable contains further information about motion drive.

In combination with this fault the variable “127: excess temperature motor warning“ is displayed on control panel. In combination with other faults the variable can be different. 



Acknowledgement

Reconnect temperature sensor

Press “Reset” 








Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel “Motion drive vertical preinsertion: fault“

	

x

x



Fault message is displayed on control panel “Motion drive vertical preinsertion: 127: excess temperature motor warning“

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x







































Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 188: MOTION DRIVE INSERTION: FAULT
FLT 191: MOTION DRIVE INSERTION + VARIABLE



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode 



Required operations

Disconnect pin 5 from plug X1 at motor control unit “40A2“ 



Consequence

Fault message is displayed on control panel “Motion drive insertion: fault“

Fault message is displayed on control panel “Motion drive insertion: 127: excess temperature motor warning“

Machine cannot be started as long as fault is active 



Comments

The variable contains further information about motion drive.

In combination with this fault the variable “127: excess temperature motor warning“ is displayed on control panel. In combination with other faults the variable can be different. 



Acknowledgement

Reconnect temperature sensor

Press “Reset” 








Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel “Motion drive insertion: fault“

	

x

x



Fault message is displayed on control panel “Motion drive insertion: 127: excess temperature motor warning“

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x









































Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	

FLT 196: MOTION DRIVE MAIN DRIVE: FAULT
FLT 198: MOTION DRIVE MAIN DRIVE + VARIABLE



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode 



Required operations

Disconnect pin 5 from plug X1 at motor control unit “1A1“ 



Consequence

Fault message is displayed on control panel “Motion drive main drive: fault“

Fault message is displayed on control panel “Motion drive main drive: 127: excess temperature motor warning“

Machine cannot be started as long as fault is active 



Comments

The variable contains further information about motion drive.

In combination with this fault the variable “127: excess temperature motor warning“ is displayed on control panel. In combination with other faults the variable can be different. 



Acknowledgement

Reconnect temperature sensor

Press “Reset”








Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel “Motion drive main drive: fault“

	

x

x



Fault message is displayed on control panel “Motion drive main drive: 127: excess temperature motor warning“

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x







































Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	

FLT 200: MACHINE: JAM AT DISCHARGE



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode

 

Required operations

Cover sensor ”=CAR1.X85-B01“



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Uncover sensor ”=CAR1.X85-B01“

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x













Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 201: DOWNSTREAM: STOP FROM MACHINE 1



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Activate SWS 60 “Line mode downstream equipment”

Press “Start”

Press “Stop” at dowstream machine



Consequence

Machine stops (downstream machine and cartoning line)

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

Disconnect input “=.K00-KI08:10“ to simulate the fault message if no downstream equipment is available

If required remove jumper



Acknowledgement

Start dowstream machine

Press “Reset”








Test result

	

	yes/no

Acceptance Criteria

Machine stops

	

x

x



Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x







































Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	

FLT 203: DOWNSTREAM: STOP FROM MACHINE 2



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Activate SWS 60 “Line mode downstream equipment”

Press “Start”

Press “Stop” at dowstream machine 2



Consequence

Machine stops

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

Disconnect input “=.K00-KI08:11“ to simulate the fault message if no downstream equipment 2 is available

If required remove jumper



Acknowledgement

Press “Start” at downstream machine 2

Press “Reset”








Test result

	

	yes/no

Acceptance Criteria

Machine stops

	

x

x



Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x









































Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	

FLT 210: GUARD OPEN: CARTON MAGAZINE



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Open guard door carton magazine



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

Test can only be performed at standstill, because guard is locked while running



Acknowledgement

Close guard door carton magazine

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x













Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	

FLT 210: GUARD 6 OPEN



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Open guard door 6



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

Test can only be performed at standstill, because guard is locked while running



Acknowledgement

Close guard door 6

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x













Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	

FLT 212: GUARD OPEN: DISCHARGE TOP



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Open guard door discharge top



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

Test can only be performed at standstill, because guard is locked while running



Acknowledgement

Close guard door discharge top

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x













Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	

FLT 212: GUARD 9 OPEN



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Open guard door 9



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

Test can only be performed at standstill, because guard is locked while running



Acknowledgement

Close guard door 9

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x













Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	

FLT 213: CARTON: OVERLOAD SIDE FLAP FOLDER



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Open guard door of cartoner

Simulate overload at sensor “=CAR1.B37-B01“ (pull guide)



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x













Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 219: CARTON BELT: LOWER POSITION NOT REACHED



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Open guard door carton magazine top

Open guard door carton belt

Lift carton belt up (“=CAR1.W31-B53” is not activated)



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Lower carton belt

Close guard door carton magazine top

Close guard door carton belt

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x





Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	

FLT 220: CARTON: STOCK AT THE END



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Empty carton magazine nearly to sensor "=CAR1.A30-B02“

Press “Start”



Consequence

Machine stops

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Fill up carton magazine

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Machine stops

	

x

x



Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x





Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 221: MACHINE: COVER RAIL OPEN



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode

Guard doors are closed



Required operations

Activate SWS 50 “Machine: cover rail” and lift up the cover rail



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Lower cover rail

Deactivate SWS “Machine: cover rail”

Press "Reset“





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x









Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 222: CARTON: CONSECUTIVE FAULT CROSSCHECK



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode

Counter consecutive fault carton crosscheck is set to 3



Required operations

Counter 210 “Carton: consecutive fault cross check“ is set to 3

Counter 240 “Carton: consecutive fault code reader“ is set to 5

Cover sensor “=CAR1.B32-B01”

Cover sensor “=CAR1.A30-B02”

Remove ≥ 3x cartons from carton magazine in front of sensor “=CAR1.A30-B01” one after the other

Press “Start” with product



Consequence

After 3 undetected cartons machine stops

Fault message is displayed on control panel



Comments

None



Acknowledgement

Uncover sensor “=CAR1.B32-B01”

Uncover sensor “=CAR1.A30-B02”

Press “Reset”








Test result

	

	yes/no

Acceptance Criteria

After 3 undetected cartons machine stops

	

x

x



Fault message is displayed on control panel

	

x

x

Comments

	

x

x













































Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	

FLT 223: CARTON: PICKUP CHECK



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in setup mode



Required operations

Cover sensor “=CAR1.A30-B04”



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Uncover sensor “=CAR1.A30-B04”

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x













Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 224: CARTON BELT: OVERLOAD



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Switch off protective motor switch “31Q10”



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Switch on protective motor switch “31Q10”

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x













Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 225: CARTON: CONSECUTIVE FAULT CODE READER



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode with product

Counter 240 ”Carton: consecutive fault code reader” is set to 3



Required operations

Place 3 cartons without or with wrong code in the carton magazine

Press “Start”



Consequence

Machine stops

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Machine stops

	

x

x



Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x





Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 226: CARTON: FAULT CODE READER



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode

SWS 200 “Code reader carton” is activated



Required operations

Disconnect input “=.K00-KI04:12”



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Reconnect input “=.K00-KI04:12”

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x











Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 227: CARTON: SENSOR MONITORING CROSSCHECK



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Cover sensor ”=CAR1-A30-B01“

Run machine for more than one cycle



Consequence

Machine stops

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Uncover sensor ”=CAR1-A30-B01“

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Machine stops

	

x

x



Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x





Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 230: GLUE UNIT: OPERATING TEMPERATURE NOT REACHED



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode

SWS 204 “Glueing” is activated



Required operations

Change temperature setpoint at Nordson glueing unit



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Set tempature setpoint at Nordson glueing unit back to previous value

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x











Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 231: GLUE UNIT: DEVICE NOT READY



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode

SWS 204 “Glueing” is activated



Required operations

Switch off glueing unit



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Switch on glueing unit

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x











Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 232: GLUE UNIT: GLUE LEVEL IS TOO LOW



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode

SWS 204 “Glueing” is activated



Required operations

Simulate low glue in glueing device (run glue empty or disconnect input “=.K00-KI02:11”



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Reconnect input “=.K00-KI02:11” if necessary

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x











Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	

FLT 235: GLUE STATION 1: SENSOR MONITORING CARTON SENSING



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode

SWS 204 “Glueing” is activated



Required operations

Disconnect sensor “=CAR1.B86-B04”



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Reconnect sensor “=CAR1.B86-B04”

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x









Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 250: CARTON REJECT 1: BIN OVERFILL



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Cover sensor ”=CAR1.Q82-B03“



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Uncover sensor ”=CAR1.Q82-B03“

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x













Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 251: CARTON REJECT 1: CROSS CHECK



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Cover sensor “=CAR1.Q82-B01“



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Uncover sensor “=CAR1.Q82-B01“

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x













Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 254: CARTON REJECT 1: SENSOR MONITORING CROSS CHECK



Test objective

Test whether correct warning message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Open guard door discharge top

Bridge guard door discharge top

Press “Start”

Cover sensor “=CAR1.Q82-B01“ permanently in case several cartons are coming



Consequence

Machine stops

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Uncover sensor “=CAR1.Q82-B01“

Remove bridge guard door discharge top

Close guard door discharge top

Press “Reset”








Test result

	

	yes/no

Acceptance Criteria

Machine stops

	

x

x



Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x









































Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	

FLT 256: PRODUCT CHAIN: OVERFILL REJECT



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Cover sensor ”80B1“



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Uncover sensor ”80B1“

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x













Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 270: CARTON: OPEN FLAP: SENSOR MONITORING COVER FLAP REAR



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode

All modules are activated in menu production switches



Required operations

Disconnect sensor “=CAR1.B86-B01”

Press “Start”



Consequence

After some cycles the Fault message is displayed on control panel



Comments

None



Acknowledgement

Reconnect sensor “=CAR1.B86-B01”

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x

Comments

	

x

x













Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	

FLT 271: CARTON: OPEN FLAP: SENSOR MONITORING COVER FLAP FRONT



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode

All modules are activated in menu production switches



Required operations

Disconnect sensor “=CAR1.B86-B02”

Press “Start”



Consequence

After some cycles the Fault message is displayed on control panel



Comments

None



Acknowledgement

Reconnect sensor “=CAR1.B86-B02”

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x

Comments

	

x

x













Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 272: CARTON: OPEN FLAP: SENSOR MONITORING SIDE FLAP REAR



Test objective

Test whether correct warning message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode

SWS 275 “Check carton open side flap” is activated



Required operations

Cover sensor "=CAR1.B86-B03“



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Uncover sensor "=CAR1.B86-B03“

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x









Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 273: CARTON: OPEN FLAP: SENSOR MONITORING SIDE FLAP FRONT



Test objective

Test whether correct warning message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode

SWS 257 “Check carton open side flap” is activated



Required operations

Cover sensor "=CAR1.B86-B04“



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Uncover sensor "=CAR1.B86-B04“

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x









Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 277: OUTFEED BELT 1: OVERLOAD



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Switch off protective motor switch “87Q10”



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Switch on protective motor switch “87Q10”

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x













Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 285: MOTION DRIVE CARTON SETUP: FAULT
FLT 288: MOTION CARTON SETUP + VARIABLE



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Disconnect pin 5 from plug X1 at motor control unit “30A1“



Consequence

Fault message is displayed on control panel “Motion drive carton setup: fault“

Fault message is displayed on control panel “Motion carton setup: 127: excess temperature motor warning“

Machine cannot be started as long as fault is active



Comments

The variable contains further information about motion drive.

In combination with this fault the variable “127: excess temperature motor warning“ is displayed on control panel. In combination with other faults the variable can be different.



Acknowledgement

Reconnect temperature sensor

Press “Reset”








Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel “Motion drive carton setup: fault“

	

x

x



Fault message is displayed on control panel “Motion carton setup: 127: excess temperature motor warning“

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x









































Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	

FLT 289: CARTON: OPEN FLAP: CONSECUTIVE FAULT COVER FLAP



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Activate SWS 256 “Check carton open cover flap“

Set counter “Consecutive fault: open cover flap“ to 3

Insert 3 cartons with open cover flap before sensor “38B1“

Press “Start”



Consequence

Machine stops

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Press “Reset”








Test result

	

	yes/no

Acceptance Criteria

Machine stops

	

x

x



Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x







































Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 294: CARTON: OPEN FLAP: CONSECUTIVE FAULT SIDE FLAP



Test objective

Test whether correct warning message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode

Counter 256 ”Carton: consecutive fault open flap” is set to 1



Required operations

Place one carton with open side flap into machine

Press “Start”



Consequence

Machine stops

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Machine stops

	

x

x



Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x



Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 300: LEAFLET: STOCK AT THE END



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Remove leaflet stack from leaflet device



Consequence

Machine stops

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Insert leaflet stack back into leaflet device

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Machine stops

	

x

x



Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x







Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 301: LEAFLET: CROSS CHECK IN PRODUCT CHAIN



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode

Product is available



Required operations

Activate SWS 300 “Leaflet device”

Press “Start” with product until leaflet gripper chain is filled up

Press “Stop”

Open guard door leaflet device

Remove leaflet before sensor ”=CAR1.A20-B01“ and after sensor ”=CAR1.A20-B02“

Close guard door leaflet device

Press “Reset”

Press “Start”



Consequence

Machine stops

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Press “Reset”








Test result

	

	yes/no

Acceptance Criteria

Machine stops

	

x

x



Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x









































Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	

FLT 302: LEAFLET: CROSS CHECK REJECT



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Place leaflet in one leaflet gripper between reject and sensor “20B4”

Press “Start”



Consequence

Machine stops

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Remove leaflet

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Machine stops

	

x

x



Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x





Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	

FLT 304: LEAFLET: CONSECUTIVE FAULT CROSS CHECK IN UNIT



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Counter 310 “Leaflet: consecutive fault cross check in device“ is set to 3

Activate SWS 300 “Leaflet device”

Deactivate SWS 302 “Leaflet: code reader rear” and/or SWS 301 “Leaflet: code reader front”

Take all leaflets out of the leaflet device (leaflet magazine)

Press “Start” with product



Consequence

Machine stops

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Fill up leaflets into the leaflet magazine

Press “Reset”








Test result

	

	yes/no

Acceptance Criteria

Machine stops

	

x

x



Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x









































Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	

FLT 305: LEAFLET: STOP AFTER MEASURE RUN



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in setup mode

Leaflets are available in the leaflet device



Required operations

Activate SWS 300 “Leaflet device“

Activate SWS 320 ”Measure run leaflet“

Press “Start”



Consequence

Machine stops after a few seconds

Fault message is displayed on control panel

Message “Measuring run completed successfully” is displayed on control panel after measure run is completed



Required operations

Confirm message by entering the "checkmark“



Comments

None



Acknowledgement

None





Test result

	

	yes/no

Acceptance Criteria

Machine stops after a few seconds

	

x

x



Fault message is displayed on control panel

	

x

x

Comments

	

x

x



Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	

FLT 307: LEAFLET: SENSOR MONITORING STOCK AT THE END



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode

SWS 300 “leaflet device” is active



Required operations

Disconnect sensor =CAR1.B28-B01



Consequence

Machine stops

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Reconnect sensor =CAR1.B28-B01

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Machine stops

	

x

x



Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x





Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	

FLT 310: GUARD OPEN: LEAFLET UNIT FRONT



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Open guard door leaflet unit front



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

Test can only be performed at standstill, because guard is locked while running



Acknowledgement

Close guard door leaflet unit front

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x













Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	

FLT 311: GUARD OPEN: LEAFLET UNIT TOP



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Open guard door leaflet unit top



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

Test can only be performed at standstill, because guard is locked while running



Acknowledgement

Close guard door leaflet unit top

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x











Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 312: GUARD OPEN: LEAFLET UNIT REAR



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Open guard door leaflet unit rear



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

Test can only be performed at standstill, because guard is locked while running



Acknowledgement

Close guard door leaflet unit rear

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x













Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	

FLT 315: GUARD OPEN: LEAFLET UNIT BOTTOM LEFT



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode 



Required operations

Open guard door leaflet unit bottom left



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Close guard door leaflet unit bottom left

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x













Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 315: GUARD 4 OPEN



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Open guard door 4



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Close guard door 4

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x













Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 316: GUARD OPEN: LEAFLET UNIT BOTTOM RIGHT



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Open guard door leaflet unit bottom right



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Close guard door leaflet unit bottom right

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x













Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 316: GUARD 5 OPEN



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Open guard door 5



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Close guard door 5

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x













Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 317: GUARD LEAFLET UNIT: SAFETY RELAY NOT ACTIVE



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Disconnect safety relay “20K18“ at connecting point “A1“



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Reconnect safety relay

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x













Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 320: LEAFLET: CONSECUTIVE FAULT CODE READER FRONT



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode

Counter 330 “Leaflet: consecutive fault code reader front“ is set to 3



Required operations

Prepare 3 leaflets with no or wrong code

Activate SWS 300 “Leaflet device”

Deactivate SWS 100 “Insert defective product”

Activate SWS 301 “Leaflet: code reader front”

Insert 3 leaflets with no or wrong code in leaflet stack successively

Press “Start” with product



Consequence

Leaflets with wrong / missing code are ejected

After 3 defective leaflets machine stops

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

To manipulate the code of the leaflet use a black felt-tip pen (e.g. Edding)



Acknowledgement

Press “Reset”








Test result

	

	yes/no

Acceptance Criteria

Leaflets with wrong / missing code are ejected

	

x

x



After 3 defective leaflets machine stops

	

x

x



Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x





































Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	

FLT 321: LEAFLET: CONSECUTIVE FAULT CODE READER REAR



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode

Counter 331 “Leaflet: consecutive fault code reader rear“ is set to 3



Required operations

Prepare 3 leaflets with no or wrong code

Activate SWS 300 “Leaflet device”

Deactivate SWS 100 “Insert defective product”

Activate SWS 302 “Leaflet: code reader rear”

Insert 3 leaflets with no or wrong code in leaflet stack successively

Press “Start” with product



Consequence

Leaflets with wrong / missing code are ejected

After 3 defective leaflets machine stops

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

To manipulate the code of the leaflet use a black felt-tip pen (e.g. Edding)



Acknowledgement

Press “Reset”








Test result

	

	yes/no

Acceptance Criteria

Leaflets with wrong / missing code are ejected

	

x

x



After 3 defective leaflets machine stops

	

x

x



Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x





































Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	

FLT 322: LEAFLET: CONSECUTIVE FAULT CROSS CHECK IN CARTON



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode

Counter 303 “Leaflet: consecutive fault cross check in carton“ is set to 3



Required operations

Activate SWS 300 “Leaflet device”

Press “Start” with product

Press “Stop” before sensor “75B4”

Open guard door

Remove 3 leaflets before sensor ”75B4“

Close guard door

Press “Reset”

Press “Start” with product



Consequence

Cartons without leaflets are ejected

After 3 missing leaflets machine stops

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Press “Reset”








Test result

	

	yes/no

Acceptance Criteria

Cartons without leaflets are ejected

	

x

x



After 3 missing leaflets machine stops

	

x

x



Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x





































Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	

FLT 324: LEAFLET: FAULT CODE READER REAR



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode with product

SWS 302 “Code reader leaflet rear” is activated



Required operations

Disconnect input “=.K00-KI04:15”



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Reconnect input “=.K00-KI04:15”

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x











Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 325: LEAFLET: SENSOR MONITORING CROSS CHECK IN CARTON



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Cover sensor “=CAR1.B75-B04“

Press “Start”



Consequence

Machine stops

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Uncover sensor “=CAR1.B75-B04“

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Machine stops

	

x

x



Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x



Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 326: LEAFLET: SENSOR MONITORING CROSS CHECK IN UNIT



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Cover sensor ”=CAR1.X161-B11“

Press “Start”



Consequence

Machine stops

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Uncover sensor ”=CAR1.X161-B11“

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Machine stops

	

x

x



Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x



Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 327: LEAFLET: SENSOR MONITORING CROSS CHECK IN PRODUCT CHAIN



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Cover sensor ”=CAR1.X161-B10“

Press “Start”



Consequence

Machine stops

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Uncover sensor ”=CAR1.X161-B10“

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Machine stops

	

x

x



Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x



Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 328: LEAFLET UNIT: END POSITION NOT REACHED BELOW



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Disconnect sensor ”20B53“



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Reconnect sensor ”20B53“

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x













Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 329: LEAFLET UNIT: ONE END POSITION DRIVE COUPLING NOT REACHED



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Disconnect sensor ”20B51“



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Reconnect sensor ”20B51“

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x











Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 330: LEAFLET UNIT: END POSITION NOT REACHED THE TOP



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Disconnect sensor ”20B52“

Open the mechanical locking on the leaflet device

Press both buttons "Lift up leaflet unit“ until leaflet unit is at the top position for approximately 10s until the fault message is displayed



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Reconnect sensor ”20B52“

Move down leaflet unit

Close the mechanical locking at the leaflet device

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x





Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	

FLT 331: LEAFLET UNIT: NOT SWIVELED IN



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Disconnect sensor ”20B54“



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Reconnect sensor ”20B54“

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x













Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 347: LEAFLET: SENSOR MONITORING CODE READER REAR



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Activate SWS 302: "Code reader leaflet rear“

Switch off machine (main switch)

Disconnect sensor “=CAR1.B75-B02“

Switch on main switch



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Reconnect sensor “=CAR1.B75-B02“

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x







Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	

FLT 382: MOTION DRIVE LEAFLET UNIT: FAULT
FLT 380: MOTION DRIVE LEAFLET UNIT + VARIABLE



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Disconnect pin 5 from plug X1 at motor control unit “20A1“



Consequence

Fault message is displayed on control panel “Motion drive leaflet unit: fault“

Fault message is displayed on control panel “Motion drive leaflet unit: 127: excess temperature motor warning“

Machine cannot be started as long as fault is active



Comments

The variable contains further information about motion drive.

In combination with this fault the variable “127: excess temperature motor warning“ is displayed on control panel. In combination with other faults the variable can be different.



Acknowledgement

Reconnect temperature sensor

Press “Reset”








Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel “Motion drive leaflet unit: fault“

	

x

x



Fault message is displayed on control panel “Motion drive leaflet unit: 127: excess temperature motor warning“

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x







































Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	

FLT 390: LEAFLET UNIT: NOT READY



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode

SWS 300 “Leaflet device” is activated



Required operations

Press “EMERGENCY STOP” strike button at leaflet device



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Unlock “EMERGENCY STOP” strike button at leaflet device

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x











Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 391: LEAFLET UNIT: OVERLOAD DRIVE EJECT



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Switch off protective motor switch “20Q11“



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Switch on protective motor switch

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x













Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 410: ROBOT: GUARD OPEN: BELT 1



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Open guard door robot belt 1



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

Test can only be performed at standstill, because guard is locked while running



Acknowledgement

Close guard door robot belt 1

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x











Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 412: ROBOT: EMERGENCY STOP ACTUATED



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode

SWS 63 “Line mode upstream equipment” is activated



Required operations

Press “Emergency stop” at robot



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Enable “Emergency stop” at robot

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x











Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 412: TLT: EMERGENCY STOP ACTUATED



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode

SWS 63 “Line mode upstream equipment” is activated



Required operations

Press “Emergency stop” at TLT



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Enable “Emergency stop” at TLT

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x











Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 413: VIAL INFEED: GUARD: SAFETY RELAY NOT ACTIVE



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode

All safety guards are closed



Required operations

Disconnect input “54K181” Pin A1



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Reconnect input “54K181” Pin A1

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x











Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 413: TLT: GUARD: SAFETY RELAY NOT ACTIVE



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode

SWS 63 “Line mode upstream equipment” is activated

All safety guards are closed



Required operations

Disconnect input “67K8” Pin A1



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Reconnect input “67K8” Pin A1

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x









Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 417: VIAL INFEED: GUARD OPEN



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Open guard door at vial infeed



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Close guard door at vial infeed

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x













Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 418: VIAL INFEED: GUARD OPEN: FRONT



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Open guard door vial infeed front



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Close guard door vial infeed front

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x













Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 421: ROBOT: GUARD OPEN: FRONT LEFT



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Open guard door robot front left



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

Test can only be performed at standstill, because guard is locked while running



Acknowledgement

Close guard door robot front left

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x











Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 422: ROBOT: GUARD OPEN: FRONT RIGHT



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Open guard door robot front right



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

Test can only be performed at standstill, because guard is locked while running



Acknowledgement

Close guard door robot front right

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x











Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 423: VIAL INFEED: EMERGENCY STOP: SAFETY RELAIS NOT ACTIVE



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Disconnect input “54K190” Pin “A1”



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Reconnect input “54K190” Pin “A1”

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x











Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 430: VIAL INFEED: BELT 1: OVERLOAD



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Switch off protective motor switch “54Q10”

Press “Start”



Consequence

Machine stops

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Switch on protective motor switch “54Q10”

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Machine stops

	

x

x



Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x





Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 431: BOTTLE INFEED: ROTARY TABLE: OVERLOAD



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Switch off protective motor switch “=CAR1.W154-Q90”

Press “Start”



Consequence

Machine stops

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Switch on protective motor switch “=CAR1.W154-Q90”

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Machine stops

	

x

x



Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x





Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 433: BOTTLE INFEED: INLET: OVERLOAD



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in setup mode



Required operations

Press “Start”

Push inlet overload mechanism “=CAR1.W154-B06”



Consequence

Fault message is displayed on control panel

Machine stops

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Bring inlet overload mechanism “=CAR1.W154-B06” to normal position

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Machine stops

	

x

x



Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x





Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 439: BOTTLE INFEED: ROTARY TABLE: FAULT



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Disconnect input “=CAR1.W154-M90” Pin “6” at clamp “=CAR1.W154-KI00”

Press “Start”



Consequence

Machine stops

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Reconnect input “=CAR1.W154-M90” Pin “6” at clamp “=CAR1.W154-KI00”

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Machine stops

	

x

x



Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x



Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	

FLT 441: VIAL INFEED: BELT 1: FAULT



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Disconnect input “54M10” Pin “1” at clamp “54A1E12”

Press “Start”



Consequence

Machine stops

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Reconnect input “54M10” Pin “1” at clamp “54A1E12”

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Machine stops

	

x

x



Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x





Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 443: VIAL INFEED: PRODUCT TIPPED OVER



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode

Vials are available



Required operations

Relocate a vial so that the sensor “54B10” is activated and sensor “54B12” is not activated



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Rearrange the vials

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x









Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 443: BOTTLE INFEED: PRODUCT TIPPED OVER



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode

Bottles are available



Required operations

Tipp over a bottle to activate the sensor “=CAR1.W154-B60” 
Sensor “CAR1.W154-B61” is not activated



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Rearrange the bottles

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x











Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	

FLT 444: VIAL INFEED: PRODUCT SENSING: CONSECUTIVE FAULT



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode

Vials are available



Required operations

Counter 430 “Vial infeed: consecutive fault product sensing” is set to 3

Press “Start” with product

Press “Stop” before sensor “54B13”

Open guard door vial infeed

Remove 3 vials in front of sensor “54B13”

Close guard door vial infeed

Press “Reset”

Press “Start”



Consequence

Machine stops

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Press “Reset”








Test result

	

	yes/no

Acceptance Criteria

Machine stops

	

x

x



Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x







































Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 446: VIAL INFEED: PRODUCT NOT TIPPED OVER



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode

Vials are available



Required operations

Press “Start” with product and erect one vial in front of sensor “54B14”



Consequence

Machine stops

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Open guard door vial infeed and tip over the vial

Close guard door vial infeed

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Machine stops

	

x

x



Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x



Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	

FLT 456: ROBOT: PRODUCT NOT PICKED UP



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode with product



Required operations

Disconnect one pneumatic piping of vacuum picker and fix it savely at the picker (e.g. by using cable tie)

Press “Start”



Consequence

Machine stops

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Reconnect the pneumatic piping

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Machine stops

	

x

x



Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x





Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	

FLT 457: ROBOT: VACUUM: FAULT



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode

Flowpack is selected as product



Required operations

Bridge guard door

Press “Start”

Disconnect input “=.W150-KI00:14”



Consequence

Machine stops

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Remove bridge of guard door

Reconnect input “=.W150-KI00:14”

Press “Reset”








Test result

	

	yes/no

Acceptance Criteria

Machine stops

	

x

x



Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x







































Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 460: TLT: NOT READY



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode

SWS 63 “Line mode upstream equipment” is activated



Required operations

Switch off TLT



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Press “Reset”

Switch on TLT





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x











Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 461: TLT: GUARD OPEN: TRANSFER/TLT FAULT RESET



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode

SWS 63 “Line mode upstream equipment” is activated



Required operations

Open guard at transfer unit TLT



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x













Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 463: TLT: WRONG OPERATION MODE



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode

SWS 63 “Line mode upstream equipment” is activated



Required operations

Activate SWS 2 “Setup“ at TLT



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x













Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 464: TLT: FAULT SPEED TOO HIGH



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode

SWS 63 “Line mode upstream equipment” is activated



Required operations

Reduce machine speed to 50% of current value

Press “Start”



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x











Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 472: VIAL INFEED: TRANSFER WHEEL: OVERLOAD



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Disconnect sensor ”54B15”



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Reconnect sensor ”54B15”

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x













Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 473: ROBOT: NO PRODUCT



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode

Flowpack is selected as product



Required operations

Bridge guard door

Press “Start”

Disconnect input “=.W150-KI00:14”



Consequence

Machine stops

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Remove bridge of guard door

Reconnect input “=.W150-KI00:14”

Press “Reset”








Test result

	

	yes/no

Acceptance Criteria

Machine stops

	

x

x



Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x







































Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 474: BOTTLE INFEED: SENSOR MONITORING PRODUCT TIPPED OVER



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode

Bottles are available



Required operations

Disconnect sensor “=CAR1.W154-B61”

Press “Start”



Consequence

Machine stops

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Reconnect sensor “=CAR1.W154-B61”

Press “Reset”








Test result

	

	yes/no

Acceptance Criteria

Machine stops

	

x

x



Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x







































Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 476: TLT: PRODUCT CHAIN NOT EMPTY



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode

SWS 63 “Line mode upstream equipment” is activated



Required operations

Disconnect sensor “60B10” or press down lever at product chain TLT



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x













Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 512: INFEED: EMERGENCY STOP ACTUATED



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Press “Emergency stop” at infeed



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Enable “Emergency stop” at infeed

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x













Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 514: INFEED: GUARD OPEN: PRODUCT CHAIN 1



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Open guard door (cover cycle belt)



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

Test can only be performed at standstill, because guard is locked while running



Acknowledgement

Close guard door (cover cycle belt)

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x











Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 517: INFEED: GUARD OPEN



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Open guard door (cover overhead conveyor)



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

Test can only be performed at standstill, because guard is locked while running



Acknowledgement

Close guard door (cover overhead conveyor)

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x











Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 530: INFEED: BELT 1: OVERLOAD



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Switch off protective motor switch “W257-Q50“



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Switch on protective motor switch “W257-Q50“

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x













Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 532: INFEED: BELT 2: OVERLOAD



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Switch off protective motor switch “W257-Q60“



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Switch on protective motor switch “W257-Q60“

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x













Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 541: INFEED: BELT 1: FAULT



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode

SWS 500 “Infeed” is activated

Inhaler is selected as product



Required operations

Press “Start”

Switch off protective motor switch “W257-Q50“



Consequence

Machine stops

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Switch on protective motor switch “W257-Q50“

Press “Reset”








Test result

	

	yes/no

Acceptance Criteria

Machine stops

	

x

x



Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x







































Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 542: INFEED: BELT 2: FAULT



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode

SWS 500 “Infeed” is activated

Corresponding product is selected as product



Required operations

Press “Start”

Switch off protective motor switch “W257-Q60“



Consequence

Machine stops

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Switch on protective motor switch “W257-Q60“

Press “Reset”








Test result

	

	yes/no

Acceptance Criteria

Machine stops

	

x

x



Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x







































Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 551: INFEED: BELT 1: PRODUCT JAM (INHALER)



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode

SWS 500 “Infeed” is activated

Inhaler is selected as product



Required operations

Cover sensor “W257-B60” (e.g. with a tape)

Press “Start”



Consequence

Machine stops

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Uncover sensor “W257-B60”

Press “Reset”








Test result

	

	yes/no

Acceptance Criteria

Machine stops

	

x

x



Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x









































Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	

FLT 554: INFEED 2: WRONG POSITION PRODUCT



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Activate SWS 500 “Infeed 2“

Disconnect sensor “67B20“



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

Fault message is displayed on control panel after delay time



Acknowledgement

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x













Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT654: INFEED 3: WRONG POSITION PRODUCT



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Activate SWS 600 “Infeed 3“

Disconnect sensor “67B30“



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

Fault message is displayed on control panel after delay time



Acknowledgement

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x













Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 902: INSERTER: CONSECUTIVE FAULT CODE READER



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode with product

Counter 901 ”Inserter: consecutive fault code reader” is set to 3



Required operations

Place 3 brochures without or with wrong code in the inserter

Press “Start”



Consequence

Machine stops

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Machine stops

	

x

x



Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x





Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 903: INSERTER: CONSECUTIVE FAULT CROSS CHECK



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode with product

SWS 901 “Inserter: Code reader” is activated



Required operations

Set counter 920 “Inserter: Consecutive fault cross check” to 3

Disconnect sensor “12B7” of inserter

Press “Start”



Consequence

Machine stops

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Reconnect sensor “12B7”

Press “Reset”








Test result

	

	yes/no

Acceptance Criteria

Machine stops

	

x

x



Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x







































Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 904: INSERTER: GUARD OPEN: HANDOVER



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Open guard door at transfer section of inserter



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

Test can only be performed at standstill, because guard is locked while running



Acknowledgement

Close guard door at transfer section of inserter

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x











Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 907: INSERTER: NOT OPERATIONAL



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode

SWS 900 “Inserter” is activated



Required operations

Disconnect input “=.X261-KI00:3”



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Reconnect input “=.X261-KI00:3”

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x











Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 922: INSERTER: EMERGENCY STOP ACTUATED



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is running with reduced speed



Required operations

Press “EMERGENCY STOP” strike button at inserter



Consequence

Machine stops

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Unlock “EMERGENCY STOP” strike button at inserter

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Machine stops

	

x

x



Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x







Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 943: INSERTER: CABINET: VOLTAGE MONITORING



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is running with reduced speed



Required operations

Switch off fuse “=CAR1.X261-F15”



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Switch on fuse “=CAR1.X261-F15”

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x













Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 947: INSERTER: SENSOR MONITORING CODE READER



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Activate SWS 901: "Code reader“

Switch off machine (main switch)

Disconnect sensor “=CAR1.B75-B05“

Switch on main switch



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Reconnect sensor “=CAR1.B75-B05“

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x





Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 1242: MOTION DRIVE CARTON ALIGNMENT: FAULT
FLT 1243: MOTION DRIVE CARTON ALIGNMENT + VARIABLE



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Disconnect pin 5 from plug X1 at motor control unit “30A2“



Consequence

Fault message is displayed on control panel “Motion drive carton alignment: fault“

Fault message is displayed on control panel “Motion drive carton alignment: 127: excess temperature motor warning“

Machine cannot be started as long as fault is active



Comments

The variable contains further information about motion drive.

In combination with this fault the variable “127: excess temperature motor warning“ is displayed on control panel. In combination with other faults the variable can be different.



Acknowledgement

Reconnect temperature sensor

Press “Reset”








Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel “Motion drive carton alignment: fault“

	

x

x



Fault message is displayed on control panel “Motion drive carton alignment: 127: excess temperature motor warning“

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x







































Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 1246: CARTON: SENSOR MONITORING CHECK CODE



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Activate SWS 200: ”Code reader carton“

Connect +24 V to camera



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Disconnect +24 V

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x











Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 1247: INSERTION: SENSOR MONITORING SAFETY SENSOR



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Disconnect sensor “=CAR1.B36-B01”



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Reconnect sensor “=CAR1.B36-B01”

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x













Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 1250: DISCHARGE BELT SLIDE IN: FAULT



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Disconnect input “I81M11“ connecting point “.3“ from plug “0A1E02“



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Reconnect input

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x













Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 1251: DISCHARGE BELT OPPOSITE SLIDE IN: FAULT



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Disconnect input “I81M10“ connecting point “.2“ from plug “0A1E02“



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Reconnect input

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x













Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 1443: ROBOT: CABINET: VOLTAGE MONITORING



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Switch off fuse “=CAR1.W150-F10”



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Switch on fuse “=CAR1.W150-F10”

Press “Reset”





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x













Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 1515: INFEED: BELT 2: PRODUCT JAM (FLOWPACK)



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode

SWS 500 “Infeed” is activated

Flowpack is selected as product



Required operations

Cover sensor “W257-B65” (e.g. with a tape)

Press “Start”



Consequence

Machine stops

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Uncover sensor “W257-B65”

Press “Reset”








Test result

	

	yes/no

Acceptance Criteria

Machine stops

	

x

x



Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x







































Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 1516: INFEED: BELT 1: PRODUCT REJECT (INHALER): BIN OVERFILL



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode

SWS 500 “Infeed” is activated

Inhaler is selected as product



Required operations

Cover sensor “W257-B62” (e.g. with a tape)

Press “Start”



Consequence

Machine stops

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Uncover sensor “W257-B62”

Press “Reset”








Test result

	

	yes/no

Acceptance Criteria

Machine stops

	

x

x



Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x







































Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 1517: INFEED: BELT 2: PRODUCT REJECT (FLOWPACK): BIN OVERFILL



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode

SWS 500 “Infeed” is activated

Flowpack is selected as product



Required operations

Cover sensor “W257-B67” (e.g. with a tape)

Press “Start”



Consequence

Machine stops

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Uncover sensor “W257-B67”

Press “Reset”








Test result

	

	yes/no

Acceptance Criteria

Machine stops

	

x

x



Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x







































Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 1518: INFEED: BELT 1: PRODUCT REJECT (INHALER): CROSS CHECK



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode

SWS 500 “Infeed” is activated

Inhaler is selected as product



Required operations

Prepare inhaler with overlength

Adjust min machine speed

Put prepared inhaler with overlength into infeed

Press “Start”



Consequence

Machine starts and ejects inhaler



Required operations

Press “Stop” immediately after inhaler was ejected

Take ejected inhaler out of collection bin and reinsert inhaler at previous position after inhaler before

Press “Start” 



Consequence

Machine stops

Fault message is displayed on control panel

Machine cannot be started as long as fault is active 



Comments

None



Acknowledgement

Remove manipulated inhaler

Press “Reset” 








Test result

	

	yes/no

Acceptance Criteria

Machine stops

	

x

x



Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x







































Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 1519: INFEED: BELT 2: PRODUCT REJECT (FLOWPACK): CROSS CHECK



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode

SWS 500 “Infeed” is activated

Flowpack is selected as product 



Required operations

Adjust min machine speed

Put two flowpacks in a row with short distance

Press “Start” 



Consequence

Machine starts and ejects flowpacks 



Required operations

Press “Stop” immediately after flowpack was ejected

Take ejected flowpack out of collection bin and reinsert flowpack at previous position with low distance

Press “Start”



Consequence

Machine stops

Fault message is displayed on control panel

Machine cannot be started as long as fault is active 



Comments

None



Acknowledgement

Take away flowpack with low distance

Press “Reset” 








Test result

	

	yes/no

Acceptance Criteria

Machine stops

	

x

x



Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x









































Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	

FLT 1543: INFEED: CABINET VOLTAGE MONITORING



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode 



Required operations

Switch off fuse “=CAR1.W257-F3052” 



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active 



Comments

None



Acknowledgement

Switch on fuse “=CAR1.W257-F3052”

Press “Reset” 





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x













Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 2001: GUARD OPEN: BIN OVERFILL



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode 



Required operations

Open guard door of ejection bin inhaler infeed



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active 



Comments

Test can only be performed at standstill, because guard is locked while running



Acknowledgement

Close guard door of ejection bin inhaler infeed

Press “Reset” 





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x











Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 2001: GUARD OPEN: SLIDE IN TOP



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode 



Required operations

Open guard door at slide in top 



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active 



Comments

Test can only be performed at standstill, because guard is locked while running 



Acknowledgement

Close guard door at slide in top

Press “Reset” 





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x











Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 2002: PRODUCT CHAIN GUARD: SAFETY RELAY NOT ACTIVE



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode 



Required operations

Disconnect input “I91S83.4“ at clamp 0A1E05 



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active 



Comments

None



Acknowledgement

Reconnect input “I91S83.4“ at clamp 0A1E05

Press “Reset” 





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x











Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 2002: INFEED: CHECK LABEL INHALER: CONSECUTIVE FAULT



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode

Product is available

Counter 2001 “Infeed: consecutive check label inhaler“ is set to 3 



Required operations

Prepare three inhalers without label

Put inhaler without label on infeed belt

Press “Start” 



Consequence

Machine stops

Fault message is displayed on control panel

Machine cannot be started as long as fault is active 



Comments

None



Acknowledgement

Press “Reset” 








Test result

	

	yes/no

Acceptance Criteria

Machine stops

	

x

x



Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x







































Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 2003: GUARD OPEN: SLIDE IN BOTTOM



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode 



Required operations

Open guard door at slide in bottom 



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active 



Comments

None



Acknowledgement

Close guard door at slide in bottom

Press “Reset” 





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x













Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 2004: INFEED: OVERHEAD CONVEYOR NOT IN LOWER POSITION



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode

Inhaler is selected as product

SWS 500 “Infeed“ is activated 



Required operations

Disconnect input “=.W257-KI02:5” 



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active 



Comments

None



Acknowledgement

Reconnect input “=.W257-KI02:5”

Press “Reset” 





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x







Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 2005: CARTON REJECT 1: CROSS CHECK CARTON REJECTED



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode

Prepare carton ejection so that sensor will not detect ejected carton (e.g. put a metal sheet above sensor that carton will fall beside the sensor) 



Required operations

Simulate a manipulated carton (e.g. Carton with wrong code)

Press “Start” 



Consequence

Carton is ejected but sensor “=CAR1.B82-B10” does not see ejected carton

Machine stops

Fault message is displayed on control panel

Machine cannot be started as long as fault is active 



Comments

None



Acknowledgement

Press “Reset” 










Test result

	

	yes/no

Acceptance Criteria

Machine stops

	

x

x



Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x





































Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 2006: CARTON REJECT 1: SENSOR MONITORING CROSS CHECK CARTON REJECTED



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode 



Required operations

Disconnect sensor “=CAR1.B82-B10” 



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active 



Comments

None



Acknowledgement

Reconnect sensor “=CAR1.B82-B10”

Press “Reset” 





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x











Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 2007: INFEED: CONSECUTIVE FAULT CHECK POSITION INHALER



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode 



Required operations

Check if counter 2003 “Infeed: Consecutive fault check position inhaler“ is set to 1

Turn one inhaler in a wrong position before infeed

Press “Start” 



Consequence

Machine stops

Fault message is displayed on control panel

Machine cannot be started as long as fault is active 



Comments

None



Acknowledgement

Press “Reset” 










Test result

	

	yes/no

Acceptance Criteria

Machine stops

	

x

x



Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x





































Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 2008: INFEED: CHECK POSITION INHALER: DEVICE NOT READY



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode 



Required operations

Activate SWS 2005 “Infeed: Check position inhaler“

Disconnect camera “position check inhaler“ 



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active 



Comments

None



Acknowledgement

Reconnect camera ”position check inhaler“

Press “Reset” 





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x









Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 2009: INFEED: CHECK POSITION INHALER: SENSOR MONITORING



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode 



Required operations

Activate SWS 2005 “Infeed: Check position inhaler“

Switch off machine (main switch)

Disconnect sensor “=CAR1.B75-A10“

Switch on machine (main switch)



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active 



Comments

None



Acknowledgement

Reconnect sensor “=CAR1.B75-A10“

Press “Reset” 





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x





Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 2010: INFEED: CHECK CAP INHALER: DEVICE NOT READY



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode

Inhaler is selected as product 



Required operations

Disconnect sensor “=CAR1.B75-B07” 



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active 



Comments

None



Acknowledgement

Reconnect sensor “=CAR1.B75-B07”

Press “Reset” 





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x











Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 2011: INFEED: CHECK CAP INHALER: TEACH PROCEDURE NOT SUCCESSFUL



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode 



Required operations

Put cap of current product half below color sensor “B75-B07” (sensor needs to see half cap color and half belt)

Activate SWS 2003 “Infeed: Check cap inhaler - Teach” 



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active 



Comments

None



Acknowledgement

Press “Reset”

Perform correct teaching of sensor 





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x









Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	

FLT 2012: INFEED: CHECK CAP INHALER: CALIBRATION PROCEDURE NOT SUCCESSFUL



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode 



Required operations

Put a reference white half below color sensor “B75-B07” (sensor needs to see half of reference white)

Activate SWS 2004 “Infeed: Check cap inhaler - Calibration” 



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active 



Comments

None



Acknowledgement

Press “Reset”

Perform correct calibration of sensor 





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x









Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	

FLT 2013: INFEED: CHECK CAP INHALER: SENSOR MONITORING



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode

Inhaler is selected as product 



Required operations

Activate SWS 2002: “Infeed: Check cap inhaler”

Disconnect sensor “=CAR1.B75-B07” 



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active 



Comments

None



Acknowledgement

Reconnect sensor “=CAR1.B75-B07”

Press “Reset” 





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x









Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 2016: INFEED: CROSS CHECK EJECT BELT 1 (INHALER): SENSOR MONITORING



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode

Inhaler is selected as product 



Required operations

Disconnect sensor “=CAR1.W257-B01” 



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active 



Comments

None



Acknowledgement

Reconnect sensor “=CAR1.W257-B01”

Press “Reset” 





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x









Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 2017: INFEED: CROSS CHECK EJECT BELT 2 (FLOWPACK): SENSOR MONITORING



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode

Flowpack is selected as product 



Required operations

Disconnect sensor “=CAR1.W257-B69” 



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active 



Comments

None



Acknowledgement

Reconnect sensor “=CAR1.W257-B69”

Press “Reset” 





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x









Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 2025: GRASP-IN PROTECTION INFEED 1 (67B16)



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode 



Required operations

Activate SWS 400 ”Infeed 1“

Remove product from infeed 1 so that sensor “67B16“ is not covered 



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active 



Comments

Fault message is displayed on control panel after delay time 



Acknowledgement

Refill infeed 1 with product until sensor “67B16“ is covered

Press “Reset” 





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x











Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 2026: STEP NUMBER NOT REACHED INF. 1 (67M12)
FLT 2030: HOME POSITION INFEED 1 (67M12)



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode 



Required operations

Activate SWS 400 “Infeed 1“

Disconnect input “12“ at control unit “67A12“ 



Consequence

Fault message is displayed on control panel FLT 2026

Fault message is displayed on control panel FLT 2030

Machine cannot be started as long as fault is active 



Comments

None



Acknowledgement

Reconnect input

Press “Reset” 





Test result

	

	yes/no

Acceptance Criteria

Fault message 2026 is displayed on control panel

	

x

x



Fault message 2030 is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x



Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 2027: STEP NUMBER NOT REACHED INF. 1 (67M13)
FLT 2031: HOME POSITION INFEED 1 (67M13)



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode 



Required operations

Activate SWS 400 “Infeed 1“

Disconnect input “12“ at control unit “67A13“ 



Consequence

Fault message is displayed on control panel FLT 2027

Fault message is displayed on control panel FLT 2031

Machine cannot be started as long as fault is active 



Comments

None



Acknowledgement

Reconnect input

Press “Reset” 





Test result

	

	yes/no

Acceptance Criteria

Fault message 2027 is displayed on control panel

	

x

x



Fault message 2031 is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x



Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	

FLT 2028: STEP NUMBER NOT REACHED INF. 1 (67M14)
FLT 2032: HOME POSITION INFEED 1 (67M14)



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode 



Required operations

Activate SWS 400 “Infeed 1“

Disconnect input “12“ at control unit “67A14“ 



Consequence

Fault message is displayed on control panel FLT 2028

Fault message is displayed on control panel FLT 2032

Machine cannot be started as long as fault is active 



Comments

None



Acknowledgement

Reconnect input

Press “Reset” 





Test result

	

	yes/no

Acceptance Criteria

Fault message 2028 is displayed on control panel

	

x

x



Fault message 2032 is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x



Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 2029: STEP NUMBER NOT REACHED INF. 1 (67M15)
FLT 2033: HOME POSITION INFEED 1 (67M15)



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Activate SWS 400 “Infeed 1“

Disconnect input “12“ at control unit “67A15“ 



Consequence

Fault message is displayed on control panel FLT 2029

Fault message is displayed on control panel FLT 2033

Machine cannot be started as long as fault is active 



Comments

None



Acknowledgement

Reconnect input

Press “Reset” 





Test result

	

	yes/no

Acceptance Criteria

Fault message 2029 is displayed on control panel

	

x

x



Fault message 2033 is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x



Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 2034: GUARD DOOR INFEED - RUNNING IN TOP - OPEN



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode 



Required operations

Open guard door infeed - running in top 



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active 



Comments

None



Acknowledgement

Close guard door

Press “Reset” 





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x













Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 2035: GUARD DOOR INFEED - RUNNING IN BOTTOM - OPEN



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode 



Required operations

Open guard door infeed - running in bottom 



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active 



Comments

None



Acknowledgement

Close guard door

Press “Reset” 





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x













Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 2036: GUARD DOOR INFEED - FRONT LEFT - OPEN (67S202)



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode 



Required operations

Open guard door infeed - front left (67S202) 



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active 



Comments

None



Acknowledgement

Close guard door

Press “Reset” 





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x













Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 2037: GUARD DOOR INFEED - FRONT CENTER - OPEN (67S203)



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode 



Required operations

Open guard door infeed - front center (67S203) 



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active 



Comments

None



Acknowledgement

Close guard door

Press “Reset” 





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x











Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 2038: GUARD DOOR INFEED - FRONT RIGHT - OPEN (67S204)



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode



Required operations

Open guard door infeed - front right (67S204) 



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active 



Comments

None



Acknowledgement

Close guard door

Press “Reset” 





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x













Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 2039: GUARD DOOR INFEED - REAR RIGHT - OPEN (67S206)



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode 



Required operations

Open guard door infeed - rear right (67S206) 



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active 



Comments

None



Acknowledgement

Close guard door

Press “Reset” 





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x













Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 2040: GUARD DOOR INFEED - REAR LEFT - OPEN (67S205)



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode 



Required operations

Open guard door infeed - rear left (67S205) 



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active 



Comments

None



Acknowledgement

Close guard door

Press “Reset” 





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x













Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 2044: PRODUCT BACKUP AT INFEED FEED 2



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode 



Required operations

Disconnect sensor “67B20“ 



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active 



Comments

None



Acknowledgement

Reconnect sensor

Press “Reset” 





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x













Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 2045: ACCELERATION BELT 2 NOT LOCKED (67B290)



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode 



Required operations

Disconnect sensor “67B290“ 



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active 



Comments

None



Acknowledgement

Reconnect sensor

Press “Reset” 





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x













Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 2046: STEP NUMBER NOT REACHED INF. 2 (67M22)
FLT 2050: HOME POSITION INFEED 2 (67M22)



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode 



Required operations

Activate SWS 500 “Infeed 2“

Disconnect input “12“ at control unit “67A22“ 



Consequence

Fault message is displayed on control panel “Step number not reached inf. 2 (67M22)“

Fault message is displayed on control panel “Home position infeed 2 (67M22)“

Machine cannot be started as long as fault is active 



Comments

None



Acknowledgement

Reconnect input

Press “Reset” 








Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel “Step number not reached inf. 2 (67M22)“

	

x

x



Fault message is displayed on control panel “Home position infeed 2 (67M22)“

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x









































Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	

FLT 2047: STEP NUMBER NOT REACHED INF. 2 (67M23)
FLT 2051: HOME POSITION INFEED 2 (67M23)



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode 



Required operations

Activate SWS 500 “Infeed 2“

Disconnect input “12“ at control unit “67A23“ 



Consequence

Fault message is displayed on control panel “Step number nocht reached inf. 2 (67M23)“

Fault message is displayed on control panel “Home position infeed 2 (67M23)“

Machine cannot be started as long as fault is active 



Comments

None



Acknowledgement

Reconnect input

Press “Reset” 








Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel “Step number nocht reached inf. 2 (67M23)“

	

x

x



Fault message is displayed on control panel “Home position infeed 2 (67M23)“

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x









































Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	

FLT 2048: STEP NUMBER NOT REACHED INF. 2 (67M24)
FLT 2052: HOME POSITION INFEED 2 (67M24)



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode 



Required operations

Activate SWS 500 “Infeed 2“

Disconnect input “12“ at control unit “67A24“ 



Consequence

Fault message is displayed on control panel “Step number not reached inf. 2 (67M24)“

Fault message is displayed on control panel “Home position infeed 2 (67M24)“

Machine cannot be started as long as fault is active 



Comments

None



Acknowledgement

Reconnect input

Press “Reset” 








Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel “Step number not reached inf. 2 (67M24)“

	

x

x



Fault message is displayed on control panel “Home position infeed 2 (67M24)“

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x









































Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	

FLT 2049: STEP NUMBER NOT REACHED INF. 2 (67M25)
FLT 2053: HOME POSITION INFEED 2 (67M25)



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode 



Required operations

Activate SWS 500 “Infeed 2“

Disconnect input “12“ at control unit “67A25“ 



Consequence

Fault message is displayed on control panel “Step number not reached inf. 2 (67M26)“

Fault message is displayed on control panel “Home position infeed 2 (67M25)“

Machine cannot be started as long as fault is active 



Comments

None



Acknowledgement

Reconnect input

Press “Reset” 








Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel “Step number not reached inf. 2 (67M26)“

	

x

x



Fault message is displayed on control panel “Home position infeed 2 (67M25)“

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x









































Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	

FLT 2055: PRODUCT BACKUP AT INFEED FEED 3



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode 



Required operations

Activate SWS 600 “Infeed 3“

Disconnect sensor “67B30“ 



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active 



Comments

None



Acknowledgement

Reconnect sensor

Press “Reset” 





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x











Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 2056: ACCELERATION BELT 3 NOT LOCKED (67B390)



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode 



Required operations

Activate SWS 600 “Infeed 3“

Disconnect sensor “67B390“ 



Consequence

Fault message is displayed on control panel

Machine cannot be started as long as fault is active



Comments

None



Acknowledgement

Reconnect sensor

Press “Reset” 





Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x











Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	




FLT 2057: STEP NUMBER NOT REACHED INF. 3 (67M32)
FLT 2061: HOME POSITION INFEED 3 (67M32)



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode 



Required operations

Activate SWS 600 “Infeed 3“

Disconnect input “12“ at control unit “67A32“ 



Consequence

Fault message is displayed on control panel “Step number not reached inf. 3 (67M32)“

Fault message is displayed on control panel “Home position infeed 3 (67M32)“

Machine cannot be started as long as fault is active 



Comments

None



Acknowledgement

Reconnect input

Press “Reset” 








Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel “Step number not reached inf. 3 (67M32)“

	

x

x



Fault message is displayed on control panel “Home position infeed 3 (67M32)“

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x









































Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	

FLT 2058: STEP NUMBER NOT REACHED INF. 3 (67M33)
FLT 2062: HOME POSITION INFEED 3 (67M33)



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode 



Required operations

Activate SWS 600 “Infeed 3“

Disconnect input “12“ at control unit “67A33“ 



Consequence

Fault message is displayed on control panel “Step number not reached inf. 3 (67M33)“

Fault message is displayed on control panel “Home position infeed 3 (67M33)“

Machine cannot be started as long as fault is active 



Comments

None



Acknowledgement

Reconnect input

Press “Reset” 








Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel “Step number not reached inf. 3 (67M33)“

	

x

x



Fault message is displayed on control panel “Home position infeed 3 (67M33)“

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x









































Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	

FLT 2059: STEP NUMBER NOT REACHED INF. 3 (67M34)
FLT 2063: HOME POSITION INFEED 3 (67M34)



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode 



Required operations

Activate SWS 600 “Infeed 3“

Disconnect input “12“ at control unit “67A34“ 



Consequence

Fault message is displayed on control panel “Step number not reached inf. 3 (67M34)“

Fault message is displayed on control panel “Home position infeed 3 (67M34)“

Machine cannot be started as long as fault is active 



Comments

None



Acknowledgement

Reconnect input

Press “Reset” 








Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel “Step number not reached inf. 3 (67M34)“

	

x

x



Fault message is displayed on control panel “Home position infeed 3 (67M34)“

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x









































Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	

FLT 2060: STEP NUMBER NOT REACHED INF. 3 (67M35)
FLT 2064: HOME POSITION INFEED 3 (67M35)



Test objective

Test whether correct fault message is displayed on control panel







Test procedure



Test prerequisites

Machine is ready in automatic mode 



Required operations

Activate SWS 600 “Infeed 3“

Disconnect input “12“ at control unit “67A35“ 



Consequence

Fault message is displayed on control panel “Step number not reached inf. 3 (67M35)“

Fault message is displayed on control panel “Home position infeed 3 (67M35)“

Machine cannot be started as long as fault is active 



Comments

None



Acknowledgement

Reconnect input

Press “Reset” 








Test result

	

	yes/no

Acceptance Criteria

Fault message is displayed on control panel “Step number not reached inf. 3 (67M35)“

	

x

x



Fault message is displayed on control panel “Home position infeed 3 (67M35)“

	

x

x



Machine cannot be started as long as fault is active

	

x

x

Comments

	

x

x









































Results comply

	yes/no

	

x

x

	Date/Initials

	

x

x

Results approved

	

x

xDate/Initials

	

Notes



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