Page - 1 / 24 -
OPERATION OF HOR 6000/2
LV 235-331-001
GENERAL
Version Final
Date 2006-09-15
Author: A. Rosiers / J. Voeten
R. Pieters / M. Sprenkels (GTD Mechanization Rsdl)
Source:
OPERATION OF HOR 6000/2
GENERAL
CONTENTS
RELEVANT DOCUMENTS ......................................................................................................................... 2
ABBREVIATIONS/TERMS.......................................................................................................................... 2
1 INTRODUCTION............................................................................................................................... 3
2 SAFETY PRECAUTIONS ................................................................................................................. 4
2.1 Emergency stop .................................................................................................................... 4
2.2 Module stops......................................................................................................................... 5
2.3 Main switch ........................................................................................................................... 6
2.4 Hand-valve for compressed-air............................................................................................. 7
2.5 Fitters lock............................................................................................................................. 8
2.6 Gas-failure safety device ...................................................................................................... 9
2.7 Push button, safety door..................................................................................................... 10
2.8 Inching cable....................................................................................................................... 12
2.9 Light signals ........................................................................................................................ 13
2.10 Horns................................................................................................................................... 13
3 MACHINE CONTROL BOX ............................................................................................................ 14
3.1 General ............................................................................................................................... 14
3.2 Reset................................................................................................................................... 15
3.3 Compressed air................................................................................................................... 16
3.4 Auxiliary equipment 1.......................................................................................................... 17
3.5 Main drive............................................................................................................................ 17
3.6 Auxiliary equipment 2.......................................................................................................... 18
3.7 Production........................................................................................................................... 18
4 HUMAN MACHINE INTERFACE (HMI) .......................................................................................... 19
4.1 General ............................................................................................................................... 19
4.2 Changing a setting .............................................................................................................. 20
4.3 Start menu and function keys (F-keys) ............................................................................... 21
F1 Messages ...................................................................................................................... 21
F2 Measurements / Settings............................................................................................... 21
F3 Lamp type ...................................................................................................................... 21
F4 Maintenance functions................................................................................................... 21
F5 Control ........................................................................................................................... 21
4.4 Menu structure .................................................................................................................... 22
4.5 Control keys (K-keys).......................................................................................................... 24
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Page - 2 / 24 -
OPERATION OF HOR 6000/2
LV 235-331-001
GENERAL
Version Final
Date 2006-09-15
RELEVANT DOCUMENTS
LV 235-331-040 Operation of Hor 6000/2, Marking and wiping machine
LV 235-331-050 Operation of Hor 6000/2, Sintering machine
LV 235-331-060 Operation of Hor 6000/2, Stem-making & mounting machines
LV 235-331-100 Operation of Hor 6000/2, Sealing& pumping mc, HF transport chain and Vert. Buffer
LV 235-331-111 Operation pressure-regulating station (Dräger)
LV 235-331-140 Operation of Hor 6000/2, Threading and capping machine
LV 235-331-145 Operation of Hor 6000/2, Cap filler
LV 235-331-160 Operation of Hor 6000/2, Flashing and testing machine
LV 235-331-180 Operation of Hor 6000/2, Distribution transport
LV 235-331-190 Operation of Hor 6000/2, Packing machines
ABBREVIATIONS/TERMS
AUX1 : Auxiliary equipment 1
AUX2 : Auxiliary equipment 2
CFM : Cap filling machine
DT : Distribution Transport
Emergency stop : This will stop a complete group of machines when de emergency stop is
pushed.
FTM : Flashing- & Testing machine
HOR : Horizontal Production Line
HMI : Human Machine Interface
LED : Light Emitting Diode
LCU : Local Control Unit
MCB : Machine Control Box
MCC : Main Control Cabinet
MJB : Machine Junction Box
MM : Mounting machine
Module stop relay : Stops the machine of which the module stop is pushed
MWM : Marking and Wiping Machine
PM : Packaging machine
PMI : Product Machine Information
SPM : Sealing- & Pumping machine
SM : Sintering machine
SMM : Stem making machine
TCM : Threading- & Capping machine
OP17 : Type number for used HMI
VB : Vertical Buffer
S:\BM\BM PMI\PMI Werkomgeving\TL (235)\LV235331\001\LV 235-331-001_eng final.doc
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Page - 3 / 24 -
OPERATION OF HOR 6000/2
LV 235-331-001
GENERAL
Version Final
Date 2006-09-15
1 INTRODUCTION
This document describes how the machines of the HOR 6000/2 group have to be operated. It relates to all
machines that are equipped with new Simatic S7 control system and are designed by Philips Lighting GTD
department. The concerning machines are mentioned in the survey of relevant documents on page 2.
Machines who does not relates to this document:
" cassette coating machine
" transport & buffer before marking & wiping machine
" transport & buffer after flashing & testing machine
" box packaging machine
This document describes the machine basic operations that are equal for all the specified machines.
The machine specific controls, messages or deviations from this LV, are described in the separate
operator manuals of the machines.
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OPERATION OF HOR 6000/2
LV 235-331-001
GENERAL
Version Final
Date 2006-09-15
2 SAFETY PRECAUTIONS
2.1 Emergency stop
Function:
To stop the complete production line at once, in case of a calamity
System is ON.
ON Conditions:
" Press the nearest emergency stop switch.
All machines of the group are stopped at once and the entire group is de-energized.
OFF " After eliminating the problem, unlock the pressed
emergency stop(s).
" Turn the main switch to  + .
" Press the push button  System switch on
If the emergency circuit is OK, the lamp in the push button goes ON.
All machines have to be started completely anew.
If the lamp stays out, the emergency circuit is not ON.
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Page - 5 / 24 -
OPERATION OF HOR 6000/2
LV 235-331-001
GENERAL
Version Final
Date 2006-09-15
2.2 Module stops
Function:
To stop the machine at once, in case of a machine failure, or risk of
injury.
ON Conditions: Compressed air is ON.
" Press the nearest module stop on the machine.
Except  Aux 1 , all other lamps on the control box extinguish.
Next is done:
" Compressed air is switched off;
" The gas control box is switched off;
" The main drive is stopped directly (not positioned)
" All drives of AUX1 and AUX2 are stopped directly.
" All equipment of AUX2 is switched off
" Part of the equipment of AUX1 is switched off (only if protected with the safety circuit= AUX1b).
OFF
" After eliminating the failure, unlock the pressed module stop.
" Press  Reset to stop the alarm.
" Start the machine according to the specific machine operation, see relevant documents.
Explanation:
With the pushbutton  Compressed air On the module stop relay is switched on if the module stop
circuit is safe. In the module stop circuit are placed:
Feed back emergency stop relay MCC. The emergency circuit of the whole group is safe.
All module stops machine
Fitter s switch on MCB
Pushbutton  Compressed air Off on MCB
Jog cable or dummy plug
Equipment AUX1a is independent of the module stop relay.
If the module stop circuit is not safe there will be a message on the OP17.
Note: Some machines do not have compressed air. For this machines the function is called  System
On/Off . The functionality is the same only there will be no switching On/Off for compressed air.
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Page - 6 / 24 -
OPERATION OF HOR 6000/2
LV 235-331-001
GENERAL
Version Final
Date 2006-09-15
2.3 Main switch
Function:
To de-energize or energize the machine and the main cabinet. For
safety reasons this is switched OFF, when electrical repairs have to be
carried out in the cabinet or on the machine.
OFF
" Turn the  MAIN SWITCH to  OFF and, if needed, lock the handle with a padlock.
" Put up a notice near the switch box, giving your name. If your name is on the padlock, this is not
necessary.
The cabinet and the machine itself are de-energized.
ON
" Make sure that no one is working at the cabinet or the machine!
" Remove padlock and turn the handle  MAIN SWITCH to  ON .
Signal lamps and signal column will be tested. Every signal lamp will light up for a short time.
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Page - 7 / 24 -
OPERATION OF HOR 6000/2
LV 235-331-001
GENERAL
Version Final
Date 2006-09-15
2.4 Hand-valve for compressed-air
Function:
The compressed air unit supplies clean compressed air at the
machine with the right pressure and humidity.
When operations have to be carried out on the machines
without compressed air on the pipes, the compressed-air
supply must be shut by turning the hand-valve.
OFF
" Turn the left, blue knob by hand. The safety valve is closed.
" Block the blue knob with a padlock.
" Take the key from the lock and keep it on you.
" Put up a notice near the padlock, giving your name. If your name is on the padlock, this is not
necessary.
No compressed air can be supplied to the machine. The system cannot be started.
ON
" Make sure that no one is working at the compressed air system!
" Remove padlock and turn the left, blue knob  ON .
The compressed air unit can be switched on.
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Page - 8 / 24 -
OPERATION OF HOR 6000/2
LV 235-331-001
GENERAL
Version Final
Date 2006-09-15
2.5 Fitters lock
Function:
To switch the safety circuit OFF/ON and lock it.
For safety reasons this must be switched OFF, during conversion and
maintenance on the machine.
OFF
" Turn the  fitters lock switch on the control panel to position  I .
" Lock the handle with a padlock. Take the key from the lock and keep it on you.
" Put up a notice on the switch, giving your name. If your name is on the padlock, this is not
necessary.
The machine drive cannot be started.
ON
" Make sure that no one is in the danger zones of the machine!
" Remove padlock and turn the  fitters lock switch to  0 .
The machine is ready to start up.
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Page - 9 / 24 -
OPERATION OF HOR 6000/2
LV 235-331-001
GENERAL
Version Final
Date 2006-09-15
2.6 Gas-failure safety device
Function:
This safety device guards against a too low pressure of fuel gas,
blower air or oxygen.
In that case the burners go out. The safety device closes the gas
valve.
This device is switched off by the emergency or module stop.
ON Conditions:  Compressed air or  System must be ON.
See the operating instructions on the gas failure safety device:
1) Make sure that the manual valve for fuel gas is closed; close it if open.
2) Open the manual valves for blower and oxygen.
3) Turn the switch to  ON .
4) Press  START, and keep it pressed until the green LEDs  valve open and  gas are on.
5) Slowly open the valve for fuel gas and ignite the burners immediately.
The gas burners are on.
If one of the green LEDs  gas ,  combustion air or  oxygen goes out, the supply pressure is too
low. See also on the intranet
" LT 02-11
" LT 94-514
OFF See the operating instructions on the gas failure safety device
1) Close the hand-valves for gas, blower and oxygen.
2) Turn the switch to  OFF .
The burners are extinguished.
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Page - 10 / 24 -
OPERATION OF HOR 6000/2
LV 235-331-001
GENERAL
Version Final
Date 2006-09-15
2.7 Push button, safety door
Function:
The screens prevent you from getting to the
dangerous parts. The screens are subdivided into
two groups:
" Fixed screens
" Gates (safety doors)
Fixed screens
The fixed screens can only be removed by means
of tools.
Gates (safety doors)
In normal situation the machine can only running if
the safety doors are closed.
Exception
If the inching cable is connected the safety door can
be opened during inching of machine.
Stop the machine
ON Conditions: Drive is ON.
" Press push button  safety door .
During stopping of the machine the light of the pressed push button  safety door and the light of
push button  drive start to flash. The machine comes to a positioned stop. If the machine is
stopped, the light inside push button  safety door is ON and light inside push button  drive is
OFF.
Open the safety door
ON Conditions: Drive is OFF
" Press push button  safety door and hold it down at same time open the safety door.
" When the door is open, release push button  safety door
The light inside the push button of the opened door is OFF. Now the machine cannot be started
up. On the OP17, you can see which door is opened. The next functions are switched OFF:
" Production
" Auxiliary equipment 2
" Drive
" Auxiliary equipment 1b
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OPERATION OF HOR 6000/2
LV 235-331-001
GENERAL
Version Final
Date 2006-09-15
Close the opened safety door
OFF
" Check if everyone is out of the danger area.
Attention! Nobody may be present in the danger area.
" Close the opened safety door.
The light of the push button  safety door is ON.
" Press the push button  Reset of the control panel, or the key  ACK of MMI.
The message on the OP17 disappears.
When all safety doors are closed and all the lights of push buttons  safety door are ON, the
machine can be started up again. See specific operation instruction of the machine.
When a safety door gives entrance to two machines, the safety door has two push buttons (each
machine has his own push button).
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Page - 12 / 24 -
OPERATION OF HOR 6000/2
LV 235-331-001
GENERAL
Version Final
Date 2006-09-15
2.8 Inching cable
Function:
To inch (run at slow speed) the machine in case of test runs or
maintenance.
The cable can be connected near the machine.
On the inching cable, next push buttons are available:
Dummy connector
" Black: Inching
" Green: Compressed air ON
" Red: Module stop
(Compressed air is OFF)
Inching cable
ON Conditions: Main switch is switched ON.
The hand-valve of compressed air is open.
Safety circuit is safe (emergency and module stops unlocked)
" Remove the dummy connector.
" Connect the inching cable. The orange lamp starts blinking.
" Press the green button. Compressed air is switched on.
" Press the black button and keep it pressed.
The horn blares for 5 seconds.
Then, the drive is switched on and the machine starts turning slowly.
If the black button is released, the machine stops.
When the black button is pressed again, within 15 seconds, the horn will not blare again.
OFF
" Remove the inching cable.
" Place the dummy connector in socket.
The machine can be started normally.
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Page - 13 / 24 -
OPERATION OF HOR 6000/2
LV 235-331-001
GENERAL
Version Final
Date 2006-09-15
2.9 Light signals
It is possible that a machine has more than one signal column. If this is the case, it will be mentioned in
the operating instruction of the specific machine, see relevant documents.
Function:
On every machine is a signal column with 5 different lamps to warn the
operator for danger and machine failures/process problems.
The orange lamp starts blinking if the inching cable is plugged and in
some cases it indicates that the machine is stand-by.
The white and blue lamps are related to the process. Actions have to be
taken.
2.10 Horns
Function:
The horn on the machine warns the operator for danger and machine
failures/process problems.
The horn goes on:
At starting up, when the main drive is switched on during 5 seconds
before the main drive starts rotating.
In inching mode, when the drive isn t been active during the last 15
seconds, the horn generates an acoustic signal before the drive is
activated during 5 seconds.
In case of an urgent process problem, see the section  Alarms in
the operation instruction of the specific machines (see relevant
documents).
The operator can find the message on the OP17 and solve the problem.
The  Reset pushbutton or the button  ACK or  ESC on the OP17 can
reset the horn. When the message is still active, the message will stay
on the OP17.
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Page - 14 / 24 -
OPERATION OF HOR 6000/2
LV 235-331-001
GENERAL
Version Final
Date 2006-09-15
3 MACHINE CONTROL BOX
3.1 General
To operate the machines of the Hor 6000/2, there is a control box near the machine. The operating panel
has several push buttons with a built-in lamp. If the lamp is continuously ON, the function of the button
concerned is normally activated.
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Page - 15 / 24 -
OPERATION OF HOR 6000/2
LV 235-331-001
GENERAL
Version Final
Date 2006-09-15
3.2 Reset
To reset all stops, warnings and horn (same function as the ACK-key).
ON Conditions: The control cabinet is switched on.
There are stops or messages active.
" Press the black push button.
The alarm sound stops and message on display disappears.
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Page - 16 / 24 -
OPERATION OF HOR 6000/2
LV 235-331-001
GENERAL
Version Final
Date 2006-09-15
3.3 Compressed air
Note: Some machines do not have compressed air. For this machines the function is called  System
On/Off . The functionality is the same only there will be no switching On/Off for compressed air.
To switch the compressed air of the machine.
ON Conditions: The main switch is ON.
The manual valve of compressed air unit is open and unit is on pressure.
Safety circuit is safe (emergency stop, fitters lock and module stops are unlocked,
dummy connector is placed)
" Press the white push button.
Lamp in the button starts blinking. Next it lights up.
If the lamp keeps blinking, the pressure is not OK. The compressed-air valve will automatically be
shut and the line is ventilated automatically.
This is also done, in case of a compressed-air dip during production.
OFF
" Press the black push button.
Lamp starts blinking. The compressed-air valve will shut and the line is ventilated automatically
Next the lamp extinguishes.
If the lamp keeps blinking the pressure stays on the line. This can give a dangerous situation.
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Page - 17 / 24 -
OPERATION OF HOR 6000/2
LV 235-331-001
GENERAL
Version Final
Date 2006-09-15
3.4 Auxiliary equipment 1
To switch the equipment that can be active without the main drive switched on.
AUX1 can be divided into 2 parts:
AUX1a (No protection by emergency or module stop)
AUX1b (Protected by emergency or module stop)
ON Conditions:
For AUX1a, there are no conditions
For AUX1b, compressed air or SYSTEM is ON.
" Press the white push button.
The lamp starts blinking or lights up.
If the lamp keeps blinking, one (or more) parts is (are) switched off by a control key (K-key on the
OP17), see section 4.1.
OFF
" Press the black push button.
The lamp extinguishes.
3.5 Main drive
To switch the main drive of the machine.
ON Conditions: Compressed air or System is ON.
" In case of a test run, warn the bystanders that the machine is going to be started!
" Press the white push button.
The drive is switched on and the signal lamp is on as soon the machine is at full speed and
synchronous in position.
OFF
" Press the black push button.
The signal lamp keeps blinking till the machine is stopped. Next the lamp extinguishes.
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Page - 18 / 24 -
OPERATION OF HOR 6000/2
LV 235-331-001
GENERAL
Version Final
Date 2006-09-15
3.6 Auxiliary equipment 2
To switch parts of the machine that need or that are allowed to start after the main drive is started.
ON Conditions:
Main drive is ON.
" Press the white push button.
The lamp starts blinking. Next, it lights up.
If the lamp keeps blinking,
" not all of the equipment is OK or
" one (or more) parts is (are) switched off by a control key (K-key on the OP17), see section 4.1.
OFF
" Press the black push button.
The lamp extinguishes.
3.7 Production
To start the production by loading products to the machine.
ON Conditions: Drive is ON.
Auxiliary equipment 2 is ON.
" Press the white push button.
The lamp lights up.
If the lamp keeps blinking, no lamps are loaded since not all of required condition are met, see the
alarm message on the TP270.
OFF
" Press the black push button.
Lamp extinguishes. The loading stops.
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Page - 19 / 24 -
OPERATION OF HOR 6000/2
LV 235-331-001
GENERAL
Version Final
Date 2006-09-15
4 HUMAN MACHINE INTERFACE (HMI)
4.1 General
This screen shows messages, settings and measurements depending the activated function key.
A
3 LED s which show next:
B
 danger: not applicable;
 help: not applicable;
 shift: the LED in on if the shift-key is pressed.
F-keys: Function keys to go through the menu s or to set values (see section 4.3).
C
K-keys: Control keys used to switch a unit ON and OFF (see section 4.5).
D
A number can be changed by pressing numeric keys. The  point stands for a  comma .
E
The +/- key is used to make a value negative or positive.
The arrow keys are used to move the cursor through a screen. The direction of the arrow indicates
F
whether you are going down or up and/or left or right.
In combination with the  shift key: browsing texts.
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Page - 20 / 24 -
OPERATION OF HOR 6000/2
LV 235-331-001
GENERAL
Version Final
Date 2006-09-15
SHIFT
" When the  shift key is pressed at the same time as the INS / DEL key, the command
G
INS is changed into DEL or the other way round.
" After pressing the  shift key, the led  shift lights up. With the arrow keys you can scroll
in the input of system parameters.
INS/DEL With this key you can overwrite or delete the underlined numeric value. INS = overwrite
and DEL = delete.
HELP This key is not used.
ESC The ESC key can be used in different ways:
1. In the menu  alarms : scrolling of the messages.
2. In all menus except  alarms : back to the previous menu (on a higher level).
3. Stopping the input of parameters without saving (undo).
ACK The ACK key is used to reset alarm messages and defined warnings.
ENTER With this key you can confirm an adjustment.
From the menu  alarms back to the main menu
4.2 Changing a setting
" The value of a setting is changeable by means of pressing the numeric keys (from 0 to 9). The  point
stands for a  comma and separates the decimals.
" Pressing the DEL key can erase the value.
" If the value is changed, the change will be filed by pressing the ENTER key.
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Page - 21 / 24 -
OPERATION OF HOR 6000/2
LV 235-331-001
GENERAL
Version Final
Date 2006-09-15
4.3 Start menu and function keys (F-keys)
Philips Lighting 23-06-05
Xxxxxxxx machine Hor 6000/2 08:23:34
F1 Messages
F2 Measurements/Settings
F3 Lamp type
F4 Maintenance functions
F5 Control
F1 F2 F3 F4 F5 F6 F7 F8
During production, the HMI-screen shows the basic screen with the production data of that moment.
To switch from the basic screen to the menu screen, press the ENTER button. One enters then a specific
menu. To go back to a previous screen, use the ESC-button. Be aware that the set values are not saved.
The submenu can have more sub-submenus or items. On can choose the menu or item with one of the
function keys (F1-F8).
The machine specific F-keys are described in the operator manuals of the machines, see relevant
documents. Next the general keys are summarized.
F1 Messages
This displays the messages.
F2 Measurements / Settings
This displays the measured process values. One can choose for general or process values.
F1 General (machine speed, product counter, etc.)
F2 Process
Most set points of lamp-type dependent process values are stored in the MCC.
Changing the lamp type to be produced makes that the corresponding set points are transferred from the
MCC to the machines.
The operator has the possibility to change the set points on the OP17. This can be done within the
ranges, which are programmed in the machine (related to the set points).
F3 Lamp type
In de menus of the lamp type, data of the lamp type is displayed.
New ordering data can only be adjusted in the OP17 of the MWM.
F4 Maintenance functions
These screens are used for maintenance. They are protected by password.
F5 Control
By the functions in this screens, stations can be blocked or released when necessary.
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Page - 22 / 24 -
OPERATION OF HOR 6000/2
LV 235-331-001
GENERAL
Version Final
Date 2006-09-15
4.4 Menu structure
Start Screen
P
F1 Messages
w
F2 Measurements/Settings
F1 General
F1 Product counter
F2 Encoder
F3 Machine
F8 <<
F2 Process
F8 <<
F3 Lamptype
F1 Lamp type current order
F2 Reload current lamp type
F8 <<
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Page - 23 / 24 -
OPERATION OF HOR 6000/2
LV 235-331-001
GENERAL
Version Final
Date 2006-09-15
P
F4 Maintenance functions
w
F1 Machine
P
F1 CAMS
w
P
F2 Timers
w
F3 IQM State
F8 <<
P
F2 System OP17
w
F1 OP-Mode
F2 Date/Time
F3 Language
F4 Password
F2 Login
F4 Logout
P
F6 Edit password
w
F8 <<
F8 <<
F8 <<
F5 Control
F1 Holders
F1 Block holder
F3 Release holder
F5 Block all holders
F7 Release all holders
F8 <<
F8 <<
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Lighting TPHI
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OPERATION OF HOR 6000/2
LV 235-331-001
GENERAL
Version Final
Date 2006-09-15
4.5 Control keys (K-keys)
The OP17 has 16 K-keys. The control key are meant for next specific functions:
K1  K4 To switch parts from AUX1 on and off.
K5  K8 To switch parts from AUX2 on and off.
K15 To turn the machine slowly, without an inching cable.
K16 To block the loading of products at the Marking & Wiping machine
The LED in the key shows the modus:
o Red is ON : The K-key is pressed, but the function deviates from the normal production
function (abnormal situation).
o Green is ON : The K-key is switched on and operates normally (production).
o LED is OFF : The K-key is not in use or is blocked.
By these colors the operator can see from a distance if there is an abnormal situation.
The machine specific K-keys are described in the operator manuals of the machines separately, see
relevant documents.
Philips
© Royal Philips Electronics The Netherlands.
Lighting TPHI
All rights reserved. Reproduction in whole or in part is
Roosendaal
prohibited without the written consent of the copyright owner