DBE-04499Deng - Display

USER MANUAL
starEX
Tape system
Display
Doc. no.: DBE-04499D Language: English

Translation of the original document
INTRODUCTION
Copyright
Drawings, installation plans and operating instructions as well as designs,
catalogues, brochures, diagrams etc. are the intellectual property of Starlinger.
Duplication, reproduction, dissemination and distribution to third parties are
prohibited. Moreover, they must not be used to produce or have produced
machines or machine components.
Great care was taken in the creation of this documentation. However, Starlinger
reserves the right to make changes and improvements to the documentation.
Warranty and liability

The individual contractual conditions pertaining to the liability and warranty or the
respective conditions of the general sales and delivery terms of Starlinger always
apply.
Starlinger accepts no liability for damage arising due to the operator failing to
adhere to the intended use.
starEX Display DBE-04499D PAGE 2 / 163

TABLE OF CONTENTS
ABOUT THIS DOCUMENT............................................................................................... 7

1 AREA OF APPLICATION ............................................................................................ 9
1.1 Function .............................................................................................................. 9
1.2 Ambient conditions .............................................................................................. 9
2 COMPONENTS AND INTERFACES......................................................................... 10
2.1 Communications interfaces ............................................................................... 10
2.2 Control panel .................................................................................................... 11
2.3 Software............................................................................................................ 11
3 CONTROL AND DISPLAY COMPONENTS .............................................................. 12
3.1 Control panel .................................................................................................... 12
3.2 User interface ................................................................................................... 12
4 BASIC INFORMATION ON OPERATION ................................................................. 13
4.1 Readiness for operation .................................................................................... 13
4.1.1 Switching on ............................................................................................. 13
4.1.2 Switching off ............................................................................................. 14
4.2 Virtual input devices .......................................................................................... 14
4.2.1 Virtual keypad ........................................................................................... 14
4.2.2 Virtual keyboard ........................................................................................ 15
4.2.3 Virtual navigation bar ................................................................................ 15
4.3 Layout of the graphical user interface ............................................................... 16
4.3.1 Status area ............................................................................................... 16
4.3.2 Working area ............................................................................................ 18
4.3.3 Navigating between menu screens ........................................................... 18
4.3.4 Navigating lists.......................................................................................... 18
4.3.5 Calculator ................................................................................................. 19
4.3.6 Screensaver ............................................................................................. 19
4.4 Controls ............................................................................................................ 19
4.4.1 Input and display fields ............................................................................. 20
4.4.2 Buttons ..................................................................................................... 20
4.5 Basic settings .................................................................................................... 21
4.5.1 “Basic settings” submenu .......................................................................... 21
4.5.2 Access concept......................................................................................... 25
4.5.3 Connection data and extruder controller ................................................... 27
4.5.4 Factory settings 1/5 .................................................................................. 29
4.5.5 Factory settings 2-4/5 ............................................................................... 30
5 WORKING WITH THE PROGRAM ........................................................................... 31
5.1 Main menu ........................................................................................................ 31
5.1.1 Overview................................................................................................... 31
5.1.2 "Calculations" submenu ............................................................................ 33

TABLE OF CONTENTS
5.1.3 "Dosing unit" submenu.............................................................................. 34

5.1.4 “Precision fibrillator” (optional) submenu ................................................... 37
5.1.5 “Fibrillator” (optional) submenu ................................................................. 40
5.2 "Extruder" submenu .......................................................................................... 42
5.2.1 Status and control of the plant area .......................................................... 42
5.2.2 Maximum values ....................................................................................... 48
5.3 "Die" submenu .................................................................................................. 49
5.4 "Water bath with take-down and holding frame" submenu................................. 53
5.4.1 Definition of terms ..................................................................................... 53
5.4.3 Oscillating knife bar .................................................................................. 59
5.5 "Hot air zone" submenu .................................................................................... 62
5.5.2 Oscillating tape ......................................................................................... 63
5.6 "Stretching and annealing unit" submenu .......................................................... 65
5.6.2 Individual drive adjustment........................................................................ 68
5.7 "Overview of heating zones" submenu .............................................................. 69
5.7.1 Extruder and die ....................................................................................... 69
5.7.2 Oil heating unit and hot air zone ............................................................... 71
5.8 "Trend" submenu .............................................................................................. 72
5.8.1 Diagram .................................................................................................... 72
5.8.2 Trend setup .............................................................................................. 76
5.9 "Report and recipe management" submenu ...................................................... 77
5.9.1 Tabs ......................................................................................................... 77
5.9.2 Displaying data ......................................................................................... 81
5.9.3 Production report ...................................................................................... 82
5.9.4 Setup report .............................................................................................. 83
5.9.5 Recipe system 1/2 .................................................................................... 85
5.9.6 Recipe system 2/2 .................................................................................... 87
5.10 “Information” submenu ...................................................................................... 88
5.10.1 Bus information ......................................................................................... 89
5.10.2 Input/Output diagnostics 1/2 ..................................................................... 90
5.10.3 Input/Output diagnostics 2/2 ..................................................................... 92
5.10.4 X2X bus modules serial numbers ............................................................. 93
5.10.5 Control data .............................................................................................. 94
5.10.6 Logbook .................................................................................................... 96
5.10.7 Reading / writing variables ........................................................................ 97
5.10.8 Hardware and software data (System Diagnostics Manager) .................... 98

TABLE OF CONTENTS
5.10.9 Drive information....................................................................................... 99

5.10.10 Pressure sensor .................................................................................. 101
5.10.11 Extruder drive with frequency converter .............................................. 102
5.10.12 Extruder drive with DC controller ......................................................... 103
5.11 “Maintenance” submenu ................................................................................. 104
5.12 “Alarm management” submenu ....................................................................... 105
5.12.1 Active alarms .......................................................................................... 105
5.12.2 User actions ............................................................................................ 107
5.12.3 Event history ........................................................................................... 108
5.13 Menu structure ................................................................................................ 111
6 MAINTENANCE ...................................................................................................... 115
6.1 Cleaning the touchscreen ............................................................................... 115
6.2 Calibrating the touchscreen............................................................................. 117
6.3 Changing the battery ....................................................................................... 118
6.4 Changing the memory card ............................................................................. 118
6.5 Software update .............................................................................................. 119
7 TROUBLESHOOTING ............................................................................................ 122
7.1 Alarm group 00 – System alarms .................................................................... 123
7.2 Alarm group 11 – Dosing unit .......................................................................... 124
7.3 Alarm group 12 – Extruder .............................................................................. 126
7.4 Alarm group 13 – Die ...................................................................................... 131
7.5 Alarm group 14 – Holding frame ..................................................................... 133
7.6 Alarm group 15 – Hot air zone ........................................................................ 138
7.7 Alarm group 16 – Stretching unit ..................................................................... 139
7.8 Alarm group 17 – Annealing unit ..................................................................... 144
7.9 Alarm group 19 – General ............................................................................... 148
7.10 Alarm group 32 – Extruder warnings ............................................................... 151
7.11 Alarm group 36 – Stretching frame warnings .................................................. 152
7.12 Alarm group 39 – General warnings ................................................................ 153
7.13 Alarm group 70 – File management ................................................................ 154
7.14 Alarm group 59 – Operating messages ........................................................... 155
7.15 Rotary encoder fault ........................................................................................ 155
7.16 Frequency converter fault ............................................................................... 157
7.17 Motor overheating ........................................................................................... 158
7.18 Motor protection/thermal relay fault ................................................................. 158
7.19 CAN bus connection fault ................................................................................ 158
7.20 <Stop> push button fault ................................................................................. 159
7.21 Overheating of the switching cabinet ............................................................... 159
7.22 Deviation from temperature tolerance ............................................................. 159

TABLE OF CONTENTS
7.23 Sensor fault..................................................................................................... 160

7.23.1 Proximity switch ...................................................................................... 160
7.23.2 Checking the thermocouple .................................................................... 161
7.23.3 Pressure sensor...................................................................................... 162

ABOUT THIS DOCUMENT
ABOUT THIS DOCUMENT
Information
This document describes how to use the central operating and control unit and is
part of the documentation series on the "starEX" tape system. This
documentation series comprises the following documents:
• General safety instructions
• Plant manual and manuals for the individual modules
• Display user manual
• Manufacturer's documentation
The documentation series is intended for use by technically qualified and trained
personnel, who are responsible for the installation, operation, maintenance and
repair of the plant. It contains all the information needed to operate the plant
safely and in the proper manner, and as such should be followed to the letter.
Compliance with the stated instructions and guidelines will also increase the
service life and optimise the performance of the plant.
NOTE!
The documentation series must always be to hand where the plant
is used and must be read and applied by each person who works
on the plant.
Notation
This manual uses the following notation:
Notation Representation Example

Reference Italics See the Layout plan
Dialog text, designation Quotation marks “Settings” menu
(Push) button, switch Angle brackets <Main switch>
Button Square brackets [Cancel]
Menu path Small caps FILE  SAVE

ABOUT THIS DOCUMENT
Indicator words
The following table provides an overview of the indicator words used and their
meaning:
Indicator word Meaning
Immediately hazardous situation which will lead to death or

DANGER! serious injuries if the safety measures are not followed
Potentially hazardous situation, which may lead to death or

WARNING! serious injuries if the safety measures are not followed
Potentially hazardous situation, which may lead to minor or

CAUTION! slight injuries if the safety measures are not followed
Possible damage to property which may occur if the safety

NOTE! measures are not followed
Pictograms
This document contains pictograms with the following meaning:
General warning
Important information
Terms and abbreviations

In this document, the "starEX" is referred to in short as "the plant". Set values and
actual values are also denoted in the document as set and actual. All other
important abbreviations are explained within the document.
Illustrations
The diagrams used in this document are example images in English, which may
deviate from your machine slightly, depending on the particular application. All
controls are governed by the specifications of the respective customer.

1. AREA OF APPLICATION
1 AREA OF APPLICATION
1.1 Function
The display is the central operating and control unit for the starEX tape system. It
consists of a control panel with a touch-sensitive screen (touchscreen), the
corresponding software with a graphical user interface and a programmable
controller with several bus systems.
The display makes it possible to perform the following actions:
• Set and view parameters
• View status information
• Monitor production processes and functions
• Activate and deactivate plant components
• Control parts of the plant manually
• Confirm alarms
1.2 Ambient conditions

The control panel may only be used under the ambient conditions specified by
the manufacturer. For further information on the control panel, see the
manufacturer's documentation.

2. COMPONENTS AND INTERFACES
2 COMPONENTS AND INTERFACES
2.1 Communications interfaces

The following diagram shows the communications interfaces of the control panel
and the other system components involved:
Ethernet X2X bus Control panel

Customer network HMI/PLC PP420
I/O modules
CAN bus
Drive switching
Stretching unit
cabinet
frequency converter
I/O modules
Heater switching
Annealing unit
cabinet
frequency converter
I/O modules
Holding frame Hot air zone

frequency converter I/O modules
Take-down Stretching frame

frequency converter I/O modules
Finishing agent
frequency converter
Extruder AC drive
Pressure sensor
(Precision) fibrillator
frequency converter
(optional)
Dosing unit
(optional)
Melt pump (optional)

2. COMPONENTS AND INTERFACES
2.2 Control panel

For a detailed description of all the components of the control panel, see the
manufacturer's documentation.
2.3 Software
The operating system and control software which are displayed on the control
panel are installed on the control computer.
NOTE!
A malfunction may be caused by third-party software.
Third-party software can impair the function of the control
software, resulting in control faults.
Do not install third-party software!
Malfunctions or damage to property due to faults resulting from

tampering with the software or installing third-party software will
void the warranty.

3. CONTROL AND DISPLAY COMPONENTS
3 CONTROL AND DISPLAY COMPONENTS
3.1 Control panel

For a detailed description of all the control and display components on the control
panel, see the manufacturer's documentation.
3.2 User interface

The screen is equipped with a touch-sensitive surface. All controls in the
graphical user interface can be operated by tapping them (touching once briefly
with the finger).
Virtual input devices are available for entering values (see Chapter 4.2).
Additional peripherals for navigation and text entry are not required.

4. BASIC INFORMATION
ON OPERATION
4 BASIC INFORMATION ON OPERATION
4.1 Readiness for operation
4.1.1 Switching on
The control panel is readied for operation automatically when the plant starts up.
The following prerequisites must be fulfilled:
• The plant is switched on
(<Main switch> is in the ON position), see the starEX plant manual).
• The control panel is properly connected.
The control panel activates and boots up when the plant starts:
1. Boot process
2. Loading of the operating system
3. Launching of the control software
Graphical user interface

After roughly 60 seconds, the main menu of the graphical user interface is
displayed and the control panel is ready for use.
The main menu is the starting point for all user actions. It serves as an overview
of all parts of the plant:
Fig. 4499/4001
• The graphical user interface is dynamic and reflects the

particular customer's specifications.
• In order to meet specific customer requirements, individual
controls may have a slightly different appearance.

ON OPERATION
4.1.2 Switching off

Switching the plant off (<Main switch> is set to OFF, see the starEX plant
manual) automatically puts the control panel out of operation. The screen turns
off.
4.2 Virtual input devices

Virtual input devices allow you to enter and amend parameters, as well as to
navigate through lists.
4.2.1 Virtual keypad

Tapping a numeric input field opens the virtual keypad (see Chapter 4.4.1).
Fig. 4499/4002
1 Valid range for the input value 2 Input value
Buttons Function
Delete input value
Change sign
Decimal point
Cancel input and close virtual keypad

 The input value is not accepted.
Confirm input and close virtual keypad
 The input value is accepted.

ON OPERATION
4.2.2 Virtual keyboard

Tapping an alphanumeric input field opens the virtual keyboard (see
Chapter 4.4.1).
Fig. 4499/4003
Buttons Function
Delete input value
Cancel input and close virtual keyboard

 The input value is not accepted.
Confirm input and close virtual keyboard
 The input value is accepted.
4.2.3 Virtual navigation bar

The virtual navigation bar opens after a value list is tapped (i.e. of alarms) and
enables the navigation and selection of list entries.
Buttons Function
Jump to the first entry
Move selection up one page
Move selection up one line
Move selection down one line
- Close navigation bar
Highlight entry
Inactive
Jump to the last entry
Move selection down one
page

ON OPERATION
4.3 Layout of the graphical user interface

The graphical user interface is broken down into two areas:
Fig. 4499/4004
1 Status area 2 Working area
4.3.1 Status area

The status area (1) is displayed in every menu, and consists of the following
controls:
Fig. 4499/4005
Selected authorisation level

1 [Additional information] button 5 indicator and [Basic settings]
button
[Main menu] button and status
2 6 Date and time
indicator
Menu number indicator and
Plant capacity indicator and
3 7 [Screenshot] or [Authorisation
status indicator
level 2] button
Active alarm indicator and
4 Alarm indicator 8
[Active alarm] button

ON OPERATION
"Menu number" indicator / [Screenshot] button

Each menu has its own unique number for identification purposes. The “Menu
number” indicator (7) shows the menu number and also serves as a button for
taking a screenshot, as follows:
1. Select authorisation level 2 (see Chapter 4.5.2)
2. Touch the [Screenshot] button for 3 seconds
 The button changes depending on the state.
 The screenshot is saved to the folder "Screenshots" in the "Report
and recipe management" submenu (see Chapter 5.9).
Button Colour Status Name / Function
Available for
Blue
selection
Button is being
Yellow Screenshot
touched
Screenshot is being
Green
saved
If authorisation level 0 or 1 is selected (see Chapter 4.5.2), the [Authorisation

level 2] button is displayed instead of the [Screenshot] button:
Button Name / Function
Authorisation level 2
Displaying / hiding additional information

2. Tap the [Additional information] button
 Depending upon the current selection and availability, additional
information (identified in the legends of various figures as “Info”) is
displayed or hidden on the menu screen.
Green Displayed
Additional information
Red Hidden

ON OPERATION
"Selected authorisation level" indicator

The "Selected authorisation level" indicator (5) shows the selected authorisation
level and also serves as a button. Tapping it opens the “Basic settings” submenu
(see Chapter 4.5.1).
"Active alarm" indicator

The “Active alarm” indicator (8) shows the active alarm and also serves as a
button. Tapping it opens the "Alarm management" submenu (see Chapter 5.12).
4.3.2 Working area

The working area (see Chapter 4.3, Fig. 4499/4004 (2)) shows different controls,
depending upon which menu is open. They allow the setting of parameters and
the execution of various functions, as described in Chapter 5.
4.3.3 Navigating between menu screens

The following buttons allow you to navigate between menu screens:
Buttons Name Function
Left
Scroll between menu
screens
Right
4.3.4 Navigating lists

The following buttons are used to navigate lists:
Buttons Name Function

Move one entry
upwards / downwards
Upwards / Downwards
or scroll report upwards /
downwards
Update the displayed
Update
data

ON OPERATION
4.3.5 Calculator
Many menu screens have a calculator, which is opened as follows:
• Tap the [Calculator] button
 The calculator is displayed.
Calculator
4.3.6 Screensaver
The screensaver is displayed automatically when the control panel has not being
used for a period of 30 minutes.
Fig. 4499/4006
Exiting the screensaver

• Tap any point on the screen
 This exits the screensaver and the last accessed menu screen is
displayed.
4.4 Controls
The graphical user interface (see Chapter 4.1.1, Fig. 4499/4001) contains various
controls with the following functions:
• Enter and display parameters
• Display operating modes
• Activate and deactivate functions

ON OPERATION
4.4.1 Input and display fields

The following fields are used to enter and display parameters:
Background Field
Example Field type
colour contents
Input field
White/Black with/without Set value
focus
Green Display field Actual value
Setting a set value

1. Tap the input field for the set value
 In numeric input fields:
This opens the virtual keypad
(see Chapter 4.2.1, Fig. 4499/4002).
 In alphanumeric input fields:
This opens the virtual keyboard
(see Chapter 4.2.2, Fig. 4499/4003).
2. Enter set value
3. Confirm your input
 The input field displays the set value.
4.4.2 Buttons
Tapping the buttons in the graphical user interface allows you to execute the
following user actions:
• Change statuses
• Execute processes
The graphical user interface uses the following types of button:
Example Representation Status Process
Activated or
Sunken Execute
switched on
Deactivated or
Raised Do not execute
switched off
Precise information on the individual buttons can be found in the description for
the respective menu.

ON OPERATION
4.5 Basic settings
To open, tap the [Basic settings] button in the main menu
In this menu, you can modify the basic settings.
4.5.1 “Basic settings” submenu
Fig. 4499/4007
1 Selected language 6 Enter date and time

2 Start of shift 7 End of shift
3 Screen brightness 8 Active shift
4 Password entry field 9 Heater timer
5 Display of the date and time 10 Heater timer date and time
Selecting the language

2. Tap the [Language selection] button repeatedly until the “Selected
language” indicator (1) shows the national flag associated with your
desired language
 The selected language is enabled.
Language selection

ON OPERATION
Setting set values

The process of setting set values is described in Chapter 4.4.1.
Setting the date and time

2. Set the date (Day-Month-Year) and time (Hour-Minute-Second) in the
respective "Date and time" input field (6)
(see Chapter 4.4.1)
3. Tap the [System time] button
 The entry is accepted as the system time.
System time
Changing units
2. Tap the [Change units] button
 The selected measuring system is accepted.
Purple / red Metric units

Change units
Imperial (English)
Green / blue
units
Setting the screen brightness

2. Set the screen brightness in field (3) (see Chapter 4.4.1)
 The screen is lit with the set brightness level.
The lower the brightness value is set, the longer the service life of
the screen.

ON OPERATION
Switching the heaters on and off

• Tap the [Heaters] button
 The heaters are switched on or off according to the selection.
Green Switched on
Heaters
Blue Switched off
Setting the heater timer

2. Tap the [Heater timer] button
 The dialog window "Heater timer" (9) is displayed.
3. Set the date (Day–Month-Year) / time (Hour–Minute) in the respective
"Heater timer date and time" input field (10)
4. Tap the [Heater timer status] button
 The [Heater timer status] button changes depending on the state.
 The heater timer is activated or deactivated according to the setting.
5. Tap the [Close dialog window] button
 The dialog window "Heater timer" (9) is closed.
 The [Heater timer] button changes depending on the state.
Buttons Representation Status / Process Name / Function

Alarm clock with
Active
flashing green dot
Heater timer
Alarm clock without
Not active
dot
Green tick Active

Heater timer status
Red cross Not active
Grey cross Close Close dialog window

ON OPERATION
Calibrating / cleaning the touchscreen

Information on calibrating the touchscreen is provided in Chapter 6.2, and on
cleaning the touchscreen in Chapter 6.1.
Buttons Name / Function
Calibrating the touchscreen
Cleaning the touchscreen
Opening the “Connection data and extruder controller” menu screen

2. Tap the [Connection data and extruder controller] button
 The “Connection data and extruder controller” menu screen opens

Connection data and extruder
controller
Opening the “Factory settings” menu screen

2. Tap the [Factory settings] button
 The “Factory settings” menu screen opens (see Chapter 4.5.4).
Factory settings

ON OPERATION
4.5.2 Access concept

By entering a password, it is possible to select different authorisation levels,
which permit the execution of certain user actions. The higher the authorisation
level, the more user actions are permitted.
User actions which require a particular authorisation level (e.g. 2) can also be
executed if a higher authorisation level (e.g. 3) is selected. All descriptions of
settings only mention the lowest authorisation level which is required.
If a higher authorisation level is already selected, the settings can be amended
immediately, without the need to switch authorisation level first.
The following table provides information about the different authorisation levels
and their associated passwords:
Authorisation Password / Indicator in the status

level Button area
0 55
1 152
3 193
4 135
All settings are saved by the controller and remain active until they are amended
(after the required authorisation level is selected). Authorisation levels 2 - 4 are
only valid for 10 minutes. After this time, authorisation level 1 is selected
automatically. Authorisation level 0 is selected automatically when the plant is
switched on.
Selecting authorisation levels 0, 1 and 3

1. Tap the password entry field (4) (see Chapter 4.5.1, Fig. 4499/4007)
 This opens the virtual keypad (see Chapter 4.2.1, Fig. 4499/4002)
2. Input the password for the authorisation level (see Chapter 4.4.1)
 Instead of the numbers, the screen displays only placeholders.
 If the password has been entered correctly, the "Selected
authorisation level" indicator in the status area changes (see
Chapter 4.3.1, Fig. 4499/4005 (5)). If the wrong password is entered,
authorisation level 0 is selected automatically.

ON OPERATION
Selecting authorisation level 2

1. Select authorisation level 1
2. Tap the [Authorisation level 2] button
 Authorisation level 2 is selected.
Authorisation level 2
Selecting authorisation level 4

1. Select authorisation level 3
2. Open the “Factory settings 1/5” menu screen (see Chapter 4.5.4)
3. Tap the password entry field (see Chapter 4.5.4, Fig. 4499/4009 (1))
 This opens the virtual keypad (see Chapter 4.2.1, Fig. 4499/4002)
4. Input the password for authorisation level 4 (see Chapter 4.4.1)
 Instead of the numbers, the screen displays only placeholders.
 If the password has been entered correctly, the "Selected
authorisation level" indicator in the status area changes (see
Chapter 4.3.1, Fig. 4499/4005 (5)).
The password for authorisation level 4 can be changed by a

Starlinger technician upon request.

ON OPERATION
4.5.3 Connection data and extruder controller
To open, tap the [Next] button

in the “Basic settings” submenu,
with authorisation level 3 selected
This menu screen allows you to check or modify all connection data and
configure the extruder speed control.
Fig. 4499/4008
1 IP address 4 SMTP server

2 Subnet mask 5 Sender e-mail address
3 Gateway 6 Recipient e-mail address 1 / 2
Setting set values

Modifying the network settings

1. Change the values (see Chapter 4.4.1)
2. Tap the [Modify network settings] button
 The new network settings are applied.
Modify network settings

ON OPERATION
Extruder speed control

When the line speed is changed, the controller automatically calculates the new
speed for all affected drives. The speed of the extruder (see Chapter 5.2) is also
changed accordingly with linear control. With exponential control, the new
extruder speed is calculated using an output curve (for setting options, see
Chapter 4.5.5).
Modifying the extruder speed control

The plant can be equipped with a melt pump (optional). This feature is only
available for operation without a melt pump!
2. Tap the [Extruder speed control] button
 The extruder speed is controlled either linearly or exponentially,
according to the selection.
Button Colour Control Name / Function
Green Linear
Extruder speed control
Blue Exponential
Opening the “Factory settings” menu screen

2. Tap the [Factory settings] button
 The “Factory settings” menu screen opens (see Chapter 4.5.4).
Factory settings

ON OPERATION
4.5.4 Factory settings 1/5

in the “Basic settings” submenu twice, with authorisation level 3
selected
On this menu screen, you can view the factory settings, which can be configured
by Starlinger technicians and loaded by the customer.
Fig. 4499/4009
Password entry for Starlinger Dialog window with prompt

1 technicians and for selecting 3 about loading the factory
authorisation level 4 settings
2 Password for authorisation level 4 4 [YES] button
Setting set values

Loading the factory settings

1. Tap the [Load factory settings] button
 The dialog window (3) is displayed, with the prompt asking whether
the factory settings should really be loaded.
2. Tap the [YES] (4) button, to confirm the prompt
 The factory settings have been loaded.
Load factory settings

ON OPERATION
4.5.5 Factory settings 2-4/5

in the "Basic settings" submenu 3 – 6 times,
These menu pages show the factory settings which were configured by Starlinger
technicians. Some settings can also be configured by the customer – after
consulting with the Customer Service Center - if authorisation level 4 is selected.
Fig. 4499/4010
NOTE!
Settings may only be configured by trained and authorised
personnel, without exception.

5. WORKING WITH THE PROGRAM
5 WORKING WITH THE PROGRAM
5.1 Main menu
To open, tap the [Main menu] button
The main menu shows a schematic representation of the entire plant and allows
you to access the submenus.
5.1.1 Overview
Fig. 4499/5001
1 Plant name Notice to close the safety cover

3 of the stretching frame (flashes
2 Customer name yellow/green)

Buttons to submenus
Tapping the buttons in the working area of the main menu opens submenus
which are described in detail in the specified chapters.
Buttons Name / Chapter Buttons Name / Chapter

Information
5.10
Extruder
5.2 Calculations
5.1.2
Overview of heating
zones
Die 5.7
5.3
Alarm management
5.12
Maintenance
Water bath with take- 5.11
down and holding
frame
Report and recipe
5.4 management 5.9
Basic settings
Hot air zone 4.5
5.5 Trend
5.8
Dosing unit (optional)
Stretching and 5.1.3
annealing unit
5.6 Precision fibrillator 5.1.4,
Fibrillator 5.1.5 (optional)

5.1.2 "Calculations" submenu
To open, tap the [Calculations] button

in the main menu
In this menu, you can made the tape calculations. These do not have a direct
influence upon the plant controller, and can therefore also be performed during
production, for the next order.
Fig. 4499/5002
1 Yarn count (set) Theoretical primary film

10
2 Tape width (set) thickness (actual)
3 Insertion width (set) 11 Film cutting width (actual)
4 Number of tapes (set) Theoretical primary film weight
12
5 Edge trim tapes (set) (actual)
6 Film width (set) Recommended melt pump
13
7 Material density (set) speed (actual)
Theoretical overall stretching
8 14 Actual melt pump speed (actual)
(set)
Calculated production weight on 15 Actual line speed (actual)
9
the winders (actual) 16 Actual stretch ratio (actual)
Setting set values

2. Set the set values (see Chapter 4.4.1)

5.1.3 "Dosing unit" submenu
To open, tap the [Dosing unit] button in the main menu
All of the relevant parameters for the dosing unit can be checked and changed in
this menu.
Fig. 4499/5003
[Blowing and suction time

1 6 Hopper status
setting] button
Display of output / type
Timeout, communication with 7
2 designation
dosing unit (info)
8 Motor status
Connection status 9 Blower status
3 • Blue: no connection 10 Pneumatic valve status
• Flashing blue and cyan: OK 11 Blowing time / suction time (set)
Alarm indicator Blowing time / suction time
12
(actual)
• Grey: ready for operation
4 [Carry over blowing and suction
• Flashing red and yellow: 13 time setting]
Fault button
5 Operating status 14 Fill level status
Setting set values


Motor status
Indicator Representation Status

Dot Stopped
Arrow pointing right Clockwise
Arrow pointing left Anticlockwise
Operating status

Green bar Active
Red circle Not active
Hopper status

Green tick OK
Cycle time
Red cross
exceeded
Pneumatic valve status
Green rectangle Open
Red rectangle Closed
Fill level status
Indicator Colour Status
Green Full
Red Empty

Showing and hiding the controls for the blowing and suction time setting
2. Tap the [Blowing and suction time setting] button (1)
 The set values (11) and buttons (13) for the blowing and suction
time setting are shown or hidden, according to the selection.
Green Controls are shown

Blowing and suction time
setting
Blue Controls are hidden
Carrying over the blowing and suction time setting

1. Show the controls for the blowing and suction time setting
2. Set the set value "Blowing time / suction time" (11) (see Chapter 4.4.1)
3. Tap the [Carry over blowing and suction time setting] button (13) for the
respective tank
 The "Blowing time / suction time" set values (11) are carried over as
the "Blowing time / suction time" actual values (12) for the respective
tank.

Carry over the blowing and
suction time setting

5.1.4 “Precision fibrillator” (optional) submenu
To open, tap the [Precision fibrillator] button

in the main menu
The plant is optionally equipped with a precision fibrillator. All of the relevant
parameters for the precision fibrillator can be checked and changed in this menu.
Fig. 4499/5004
Pressure roller actual position

1 7 Full speed (info)
(actual)
2 Pressure roller position indicator 8 Control type legend (info)
3 Working position (set) Precision fibrillator speed
9 (set/actual) / Control type
4 Stepper motor status (actual) (actual/set)
Needle roller operation time
5 Referencing status 10
(actual)
6 Tip way (info) 11 Clutch / tape guide status
Precision fibrillator status

Green bar Active

Referencing status

Green bar Referenced
Red circle Not referenced
Clutch / tape guide status

Green bar OK
Grey bar Fault
Saving the working position

2. Tap the [Save working position] button
 The working position of the precision fibrillator is saved.
Save the working position
Referencing the stepper motor

2. Tap the [Reference stepper motor] button
 The stepper motor is referenced.
 The referencing status indicates whether the stepper motor is
referenced.
Reference stepper motor

Resetting a stepper motor fault

• Tap the [Reset stepper motor fault] button
 The stepper motor fault is reset
Reset a stepper motor fault
Resetting the needle roller operation time

2. Tap the [Needle roller operation time] button
 The needle roller operation time is reset.

Reset the needle roller operation
time
Opening the "Drive information" menu screen

1. Display additional information (see Chapter 4.3.1)
 The [Drive information] button is activated.
2. Tap the [Drive information] button
 The “Drive information” menu screen opens (see Chapter 5.10.9).
Drive information

5.1.5 “Fibrillator” (optional) submenu
To open, tap the [Fibrillator] button in the main menu
The plant is optionally equipped with a fibrillator. All of the relevant parameters for
the fibrillator can be checked and changed in this menu.
Fig. 4499/5005
Fibrillator speed (set Pneumatic valve status, working

1 calculated/actual) / Control type 3 position sensor, waiting position
(actual/set) sensor (info)
Needle roller operation time
2 Control type legend (info) 4
(actual)
Pneumatic valve status
Green rectangle Open
Red rectangle Closed
Green bar Signal present
Grey bar No signal

Fibrillator status

Green bar Active
Resetting the needle roller operation time

2. Tap the [Needle roller operation time] button
 The needle roller operation time is reset.

Reset the needle roller operation
time

 The [Drive information] button is activated.
 The “Drive information” menu screen opens (see Chapter 5.10.9).
Drive information

5.2 "Extruder" submenu
To open, tap the [Extruder] button in the main menu
All of the relevant parameters for the extruder can be checked and changed in
this menu.
5.2.1 Status and control of the plant area
Fig. 4499/5006
Temperature change for all Heater status, temperature of all

1 8
heating zones (set) heating zones (set/actual)
Gear oil temperature (actual)
Heating times / cooling times
2 9 and [Maximum values] button
(info)
(info)
Melt pressure before die
Motor temperature (actual) and
3 indicator and [Pressure sensor] 10
[Extruder drive] button (info)
button (info)
Melt pressure before filter
Cooling system status / infeed
zone temperature (set/actual)
button (info)
Melt pressure after filter
Position and program step for
infeed zone servo valve (info)
button (info)
Melt pump speed, drive Extruder speed, drive utilisation
6 13
utilisation (set/actual) (actual)
7 Temperature for all zones (set) 14 Material switching notice

Heater / cooling system status

Green bar Operating, temperature OK
Red circle Not operating
Wavy lines For heater only: heater enabled
For cooling system only: cooling system
Crystals
enabled
Exclamation mark Sensor break or
(flashing yellow/red) over/undertemperature
The number of heating zones (8) can vary with the size of the
extruder.
Extruder / melt pump status

Green bar Active
Temperature release
The temperature release ensures that the extruder cannot be switched on until all
of the material in the cylinder has completely plasticised.
When one of the die heating zones reaches 160°C, the extruder heating zones
are heated up. If the infeed zone exceeds 80°C (due to insufficient or a total
absence of cooling water), extruder zone 1 switches off in order to cool the infeed
zone.
Once all temperatures of the heaters are within the set tolerances, the extruder
heats up for 60 minutes (fixed factory setting). The heating-through period is 90
minutes when operating with a melt pump (optional).
The time remaining is shown in the status area (see Chapter 4.3.1, Fig.
4499/4005). The extruder can be started once the time period has elapsed.
During operation, if the temperature of a heating zone falls below 190°C when
supplying PP or 230°C for HDPE, the plant stops automatically and the heating-
through period starts from scratch.

Setting set values

Setting the temperature for all heating zones

2. Set the desired temperature (see Chapter 4.4.1)
3. Tap the [Adopt temperature] button
 The set temperature is adopted by all heating zones.
Adopt temperature
Setting the temperature change for all heating zones

2. Set the set value "Temperature change for all heating zones" (1)
(see Chapter 4.4.1)
3. Tap the [Temperature change for all zones] button
 According to the selection, the value in the field "Temperature
change for all heating zones" (1) and consequently also the
temperature for all heating zones is increased or reduced by the set
value.
Buttons Representation Process Name / Function
Plus sign Increase temperature

Temperature change
for all zones
Minus sign Reduce temperature

Activating and deactivating standby temperature

So that the material is not burned during brief interruptions to production, a
standby temperature of 200°C can be activated. While the standby temperature
is active, it is not possible to start up the plant. The function is activated and
deactivated as follows:
2. Tap the [Standby temperature] button
 This activates or deactivates the standby temperature according to
the selection.
Green Active
Standby temperature
Blue Not active
Switching materials
2. Tap the [Material] button
 The processing temperature and output curve are adjusted for the
supply of HDPE or PP, depending on the selection.
Button Colour Supply Name / Function
Green HDPE
Material
Blue PP
When switching materials from PP to HDPE, make sure that all

heating zones are heated through to more than 230°C. Otherwise
the notice (14) is displayed.

Activating and deactivating film thickness control

When film thickness control is activated, the extruder speed is corrected
incrementally by the thickness measurement device (optional) until the film
thickness set on the thickness measurement device is achieved.
This kind of extruder control depends on the continuous measurement of the film
thickness over the entire area of the film and is therefore independent of the
extruder speed set value.
2. Tap the [Film thickness control] button
 This activates or deactivates film thickness control according to the
selection.
Green Active
Film thickness control
Blue Not active
Activating and deactivating die cleaning

During production, the extruder speed may not be increased or reduced by more
than 5 rpm. The activation of die cleaning disables this protective function,
allowing larger changes in speed.
2. Tap the [Die cleaning] button
Button Representation Process Name / Function

Speed increment
Green
> 5 rpm
Die cleaning
Speed increment
Blue
max. 5 rpm

Opening the “Maximum values” menu screen

 The [Maximum values] button is activated
2. Tap the [Maximum values] button
 The “Maximum values” menu screen opens (see Chapter 5.2.2).
Maximum values
Opening the “Extruder drive” menu screen

 The [Extruder drive] button is activated
2. Tap the [Extruder drive] button
 On plants where the extruder drive is equipped with a frequency
converter: The “Extruder drive with frequency converter” menu
screen opens (see Chapter 5.10.11).
 On plants where the extruder drive is equipped with a DC controller:
The “Extruder drive with DC controller” menu screen opens (see
Chapter 5.10.12).
Extruder drive
Opening the “Pressure sensor” menu screen

 The [Pressure sensor] button is activated.
2. Tap the [Pressure sensor] button
 The “Pressure sensor” menu screen opens (see Chapter 5.10.10).
Pressure sensor

5.2.2 Maximum values
To open, tap the [Maximum values] button

in the “Extruder” submenu,
with authorisation level 3 and additional information selected
This menu screen displays the last 10 maximum values for the following
parameters:
• Extruder screw speed / motor current / motor temperature
• Rotor temperature
• Pump utilisation / pump speed
• Chiller
• Extruder motor cooling water supply / return
• Extruder drive temperature
Fig. 4499/5007
1 Maximum values (actual) 2 Current value (actual)
Selecting a parameter
• Tap the [Parameter] button
 The values for the selected parameter are displayed.
Parameter

5.3 "Die" submenu
To open, tap the [Die] button in the main menu
All of the relevant parameters for the die can be checked and changed in this
menu.
Fig. 4499/5008
Die heating zone utilisation

1 Melt pressure indicator 6 (info) / status / temperature
(set/actual)
Heating zone for filter, melt 7 Filter tape feed indicator
pump (optional), static mixer
2 Heating zone utilisation (info) /
and adapter utilisation (info) / 8
status / temperature (set/actual) status / temperature (set/actual)
Waiting time after the heating
Extruder drive status / speed 9 process for the filter tape feed
3 (set/actual)
(actual) / utilisation (actual)
10 Heating time (set/actual)
Melt pump drive status / speed 11 Differential pressure (set/actual)
4
(set/actual) / utilisation (actual) 12 Melt temperature (actual)
5 Melt temperature (set) 13 Warning pressure (set)

Extruder / melt pump status

Green bar Active
Heater status

Green bar Operating, temperature OK
Red circle Not operating
Wavy lines Heater enabled
Yellow exclamation mark Sensor break or over/undertemperature
Setting set values

Automatic filter tape feed

If automatic filter tape feed is active and the difference between the melt pressure
before and after the filter exceeds the set differential pressure (11), a filter tape
feed is performed.
In order for the material to solidify on the filter tape, there must be a cooling
period between two filter tape feeds.
For procedural reasons and in order to keep the differential pressure as low as
possible, a regular filter tape feed with short feed lengths is recommended.
This is achieved by setting the differential pressure (11) as low as possible, so
that it is permanently exceeded and an automatic filter tap feed occurs regularly,
at an interval determined by the cooling period.
Depending on the material, this may require the temperature of Zone 10 to be set
to approx. 35-40°C. In the ideal situation, this will mean a feed length of approx.
4-5 mm per filter tape feed.
Changing the line speed causes pressure fluctuations. The

differential pressure (11) should therefore only be adjusted after
the production speed is reached.

Automatic or manual filter tape feed
CAUTION!
Risk of burns from the escaping melt!
If manual filter tape feed is activated, the filter tape heater is
permanently active. This can cause melt to escape from the filter.
Wear protective gloves when manual filter tape feed is selected!

2. Tap the [Filter tape feed] button
 The filter tape feed indicator (7) changes appearance, depending on
the state.
 The filter tape feed is performed either automatically or manually,
depending on the selection.
Red Manual
Filter tape feed
Blue Automatic
Setting the temperature for all heating zones

2. Set the desired temperature (see Chapter 4.4.1)
3. Tap the [Adopt temperature] button
 The set temperature is adopted by all heating zones.
Adopt temperature

Activating and deactivating die cleaning

During production, the extruder speed may not be increased or reduced by more
than 5 rpm. The activation of die cleaning disables this protective function,
allowing larger changes in speed.
2. Tap the [Die cleaning] button

Speed increment
Green
> 5 rpm
Die cleaning
Speed increment
Blue
max. 5 rpm
Activating and deactivating the alarm at warning pressure

2. Set warning pressure (13) (see Chapter 4.4.1)
3. Tap the [Alarm at warning pressure] button
 If the warning is activated, an alarm is displayed when the warning
pressure is reached. Otherwise, no alarm occurs.

Green Active
Alarm at warning pressure
Blue Not active

Pressure sensor

5.4 "Water bath with take-down and holding frame" submenu
5.4.1 Definition of terms
Fig. 4499/5009
1 Annealing unit = Line speed 5 Annealing ratio

2 Stretching unit 6 Stretch ratio
3 Holding frame 7 Cutting tension
4 Take-down 8 Total stretch ratio
The speed between take-down and holding frame is particularly important for
achieving the very best web tension for the tape cutting process. The basic
setting of the holding frame is calculated from the line speed (= speed of the last
galette of the annealing unit (1)) and the total stretch ratio (8).
The total stretch ratio is the stretching between the holding frame (3) and the
annealing unit (1), and represents one of the two basic parameters.
The line speed (1) is the second basic parameter of the plant controller. It is
dependent on the material and can be adjusted on the control panel of the
stretching frame (see the starEX module manual).
The speed ratios stipulated by the basic parameters are always retained by the
synchronised behaviour of the drives.
The stretch ratio (6) is the ratio of the speed at the holding frame (3) to the speed
of the stretching unit (2). The stretch ratio is calculated automatically by the
controller, depending on the basic parameters.
The annealing ratio (5) is the ratio of the speed of the stretching unit (2) to the
line speed (1).
If the speed of the annealing unit (1) is modified, the controller adjusts the speed
of the stretching unit (2) such that the total stretch ratio remains the same.

To open, tap the [Water bath with take-down and holding frame]
button in the main menu
This menu is used to control the take-down and holding frame and check and
change their parameters.
Fig. 4499/5010
Take-down 2* [Drive Water bath status / temperature

1 10
information] button (info) (set/actual)
2 [Web tension] buttons Melt pressure before filter / after
[Web tension] buttons, take- 11 filter / before die and [Pressure
3 sensor] button (info)
down holding frame
Take-down 2* status / speed
Web tension between take-
4 12 (set calculated/actual) / Control
down and holding frame (actual)
type (actual/set)
Web tension] buttons, take-
Holding frame status / speed 13
down 1 to take-down 2*
5 (set calculated/actual) /
Control type (actual/set) Web tension between 1st and
14
2nd take-down* (actual)
Melt pump status / speed
Take-down 1 [Drive information]
6 15 (set/actual) / Control type
button (info)
(actual/set)
7 Control type legend 16 Servo valve position (info)
Extruder status / speed
Holding frame [Drive
8 17 (set/actual) / Control type
information] button (info)
(actual/set)
Take-down 1 status / speed (set
Cooling system supply
9 calculated/actual) / Control type 18
temperature (actual)
(actual/set)
* Optional

Setting set values

Extruder / take-down / holding frame / melt pump status

Green bar Active
Activating and deactivating startup assistance

Startup assistance prevents the take-down and holding frame from being
overloaded by heavy tapes. If the line speed falls below 120 m/min, with startup
assistance activated, the web tension is reduced until a line speed of 120 m/min
is achieved again. The web tension may then be increased again.
2. Tap the [Startup assistance] button
 Startup assistance is activated or deactivated according to the
selection.
 With startup assistance activated, the fields (4) and (14) flash yellow
and green.
Flashes yellow and green Activated

Startup assistance
Blue Deactivated

Pressure sensor

Switching the injector exhauster (optional) on and off

2. Tap the [Injector exhauster] button
 The injector exhauster is switched on or off depending on the
selection.
Green Switched on
Injector exhauster
Blue Switched off
Switching the edge strip extractor on and off

2. Tap the [Edge strip extractor] button
 The edge strip extractor is switched on or off depending on the
selection.
Green Switched on
Edge strip extractor
Blue Switched off
Switching the cooling water pump on and off

2. Tap the [Cooling water pump] button
 The cooling water pump is switched on or off depending on the
selection.
Green Switched on
Cooling water pump
Blue Switched off

Switching film drying on and off

2. Tap the [Film drying] button
 Film drying is switched on or off depending on the selection.
Green Switched on
Film drying
Blue Switched off
Increasing and reducing web tension

The web tension between the 1st and 2nd take-down (optional) as well as
between the take-down and the holding frame can be increased or reduced with
the [Web tension] buttons. The current web tension is saved at a line speed of
between 100 and 120 metres/min.
2. Tap the [Web tension] button
 The web tension is increased or reduced, according to the selection,
in increments of 0.02 m/min.
Plus sign Increase web tension

Web tension
Minus sign Reduce web tension
Opening the “Oscillating knife bar” menu screen

• Tap the [Oscillating knife bar] button
 The “Oscillating knife bar” menu screen opens (see Chapter 5.4.3).
Oscillating knife bar

Switching the take-down 1 motor between clockwise and anticlockwise

operation (optional)
1. Stop the plant (see the starEX plant manual)
 The [Motor clockwise/anticlockwise] button is displayed.
2. Touch the [Motor clockwise/anticlockwise] button
 The motor of take-down 1 runs either clockwise or anticlockwise,
Green Anticlockwise Motor

clockwise/anticlockwise
Blue Clockwise operation

 The [Drive information] buttons are activated.
 The “Drive information” menu screen for the respective area opens
Buttons Area Name / Function
Holding frame
Take-down 2
Drive information
(optional)
Take-down 1

5.4.3 Oscillating knife bar
To open, press the [Oscillating knife bar] button

in the "Water bath with take-down and holding frame" submenu
All of the relevant parameters for the oscillating knife bar can be checked and
changed on this menu screen.
Fig. 4499/5011
Oscillating motor status, sensor zero

1 Interval (set) 3
position, sensor channel 1 (info)
Knife bar operation time 4 Elevation (set)
2
(actual) 5 Penetration indicator
Setting set values

Oscillating motor status, sensor zero position, sensor channel 1

Dot Stopped
Grey bar No signal

Switching the oscillating knife bar on and off

2. Tap the [Oscillating knife bar] button
 The oscillating knife bar is switched on or off depending on the
selection.
Green Switched on
Blue Switched off
Controlling the penetration of the knife manually

2. Touch the [Knife penetration] button
 The position of the film is modified in accordance with the process,
such that the penetration of the knife increases or decreases while
the operator is touching the respective button.
Arrow pointing left Reduce penetration

Knife penetration
Arrow pointing right Increase penetration
Resetting the knife bar operation time

2. Tap the [Reset knife bar operation time] button
 The knife bar operation time (2) is reset to "0".

Reset the knife bar operation
time
The knife bar operation time (2) assists in determining the life of
the knife and should be reset after a knife change.

Positioning the film in the zero position of the knife

2. Tap the [Knife zero position] button
 The film is positioned in such a way that the knife can achieve the
maximum penetration (zero position).
Knife zero position
Adjusting the elevation

2. Tap the [Elevation] button
 The value in the field Elevation (4), and consequently also the
elevation of the knife bar, is increased or reduced according to the
selection.
Up arrow Increase elevation

Elevation
Down arrow Decrease elevation
For heavy ribbons, the elevation should be kept low, to prevent

the film jumping off from the blades. The elevation can be raised
for light tapes.

5.5 "Hot air zone" submenu
To open, tap the [Hot air zone] button in the main menu
All of the relevant parameters for the hot air zone can be checked and changed in
this menu.
Fig. 4499/5012
Oil heating unit status /

1 Precision fibrillator (optional) status /
temperature (set/actual)
7 speed (set) / (actual) / drive
Hot air zone status / utilisation (actual)
2
Melt pressure before filter / after filter
Blower (optional) output
3 8 / before die and [Pressure sensor]
(set)
button (info)
Stretching unit drive 1, 2
Take-down 2 (optional) status /
status / speed (set
4 9 speed (set calculated/actual) / drive
calculated/actual) / drive
utilisation (actual)
utilisation (actual)
Line, finishing agent status / Holding frame, take-down 1 status /
5 speed (set) / speed (actual) 10 speed (set calculated/actual) / drive
/ drive utilisation (actual) utilisation (actual)
Melt pump, extruder status / speed
Total stretch ratio 11 (set) / speed (actual) / drive
6 utilisation (actual)
(set=actual)
12 Stretch ratio (actual)

Drive status

Green bar Active
Setting set values

Opening the “Oscillating tape” menu screen

• Tap the [Oscillating tape] button
 The “Oscillating tape” menu screen opens (see Chapter 5.5.2).
Oscillating tape

Pressure sensor
5.5.2 Oscillating tape
To open, tap the [Oscillating tape] button

in the "Hot air zone" submenu
All of the relevant parameters for the oscillating tape can be checked and
changed on this menu screen.

Fig. 4499/5013
1 Oscillating tape status

Oscillating motor status /
2 Waiting time (set/actual) 4
left sensor / right sensor
3 Moving time (set/actual)
Setting set values

Oscillating motor status / left sensor / right sensor

Dot Stopped
Grey bar No signal
Oscillation status
Indicator Colour Status
Green Active
Red Not active

5.6 "Stretching and annealing unit" submenu
To open, tap the [Stretching and annealing unit] button

in the main menu
All of the relevant parameters for the stretching and annealing unit can be
checked and modified in this menu.
Fig. 4499/5014
1 Tape length 1 / 2 (set/actual) Precision fibrillator status /

8 speed (set/actual) / control type
2 Control type legend (actual/set)
Ratio between the two drives of
3 Annealing ratio (actual) 9
the stretching unit (actual)
Line status / speed (set/actual) / Stretching unit drive 1, 2 status /
4 control type (actual/set) / drive 10 speed (set/actual) / control type
utilisation (actual) (actual/set)
Stretching frame status / Valve position (info)
5
temperature (set/actual) 11 • 0 = open
6 Total stretch ratio (set) • 125 = closed
Oil heating unit status /
7 12 Stretch ratio (actual)

Drive / tape length counter status

Green bar Active
Method of operation of the tape length counter

Each time the plant is switched on with the <Main switch>, the tape length
counter must be reactivated. The length of tape which is to be wound must be set
as the set value (1).
You can determine whether the tape length counter is active by the actual value
(1) rising and from the blue-lit <Reset> button on the control panel of the
annealing unit (see the starEX module manual).
If the current tape length (1) reaches the set value on one or both tape length
counters, the <Reset> button flashes and the rotating mirror beacon lights up.
Pressing the <Counter reset> button on the annealing unit control panel (see the
starEX module manual) resets the respective tape length counter to "0", provided
that the set tape length has been reached.
The [Reset tape length counter] button can be used to reset the tape length
counters to "0" at any time, i.e. even before the set tape length (1) is reached.
Setting set values

Resetting the tape length counter

2. Tap the [Reset tape length counter] button
 The tape length counter in question is reset to "0".
Button Name
Reset the tape length counter

Switching the cooling water pump on and off

2. Tap the [Cooling water pump] button
 The cooling water pump is switched on or off depending on the
selection.
Green Switched on
Cooling water pump
Blue Switched off
When the stretching frame starts up, the cooling water pump is
switched on automatically.
Changing the speed adjustment mode

If the speed of the annealing unit is changed, in "collective adjustment" mode the
speeds of all the remaining galettes are automatically adjusted accordingly. In
"individual drive adjustment" mode, the remaining galettes are not affected by the
change in speed.
2. Tap the [Speed adjustment mode] button
 The speed adjustment occurs either in individual drive adjustment
mode or in collective adjustment mode, depending on the selection.

Individual drive
Green
adjustment
Speed adjustment mode
Blue Collective adjustment

5.6.2 Individual drive adjustment
To open, tap the [Speed adjustment mode] button

in the “Stretching and annealing unit” submenu,
An individual drive adjustment is made on this menu screen.
Fig. 4499/5015
Selected units
2
Deselected unit (with blue background)
1
(with grey background) Speed adjustment difference
3
(set)
Setting set values

Resetting all drives to the line speed

2. Tap the [Line speed] button
 The speed of all drives is reset to line speed.
Button Name
Line speed

Increasing and reducing the speed

2. Select units by tapping them
 The selected units have a blue background.
3. Tap the [Speed adjustment] button
 The speed is increased or reduced by the difference (3), depending
on the selection.
Plus sign Increase speed

Speed adjustment
Minus sign Reduce speed
5.7 "Overview of heating zones" submenu
To open, tap the [Overview of heating zones] button

in the main menu
The menu shows the switch-on duration of the heaters for the respective heating
zone, within the black bars. Potential faults with a heater or fuse can be
recognised here from the high switch-on duration.
5.7.1 Extruder and die
Fig. 4499/5016

Opening the “Extruder” menu screen

• Tap the [Extruder] button
 The “Extruder” menu screen opens (see Chapter 5.2).
Button Name
Extruder
Opening the “Die” menu screen

• Tap the [Die] button
 The “Die” menu screen opens (see Chapter 5.3).
Button Name
Die
Resetting switch-on duration

2. Tap the [Reset switch-on duration] button
 The switch-on duration is reset.

Reset switch-on
duration

5.7.2 Oil heating unit and hot air zone

in the "Overview of heating zones" submenu
This menu screen shows the switch-on duration of the heaters for the respective
heating zone, within the black bars. Potential faults with a heater or fuse can be
recognised here from the high switch-on duration.
Fig. 4499/5017
Opening the “Stretching and annealing unit” menu screen

• Tap the [Stretching and annealing unit] button
 The “Stretching and annealing unit” menu screen opens (see
Chapter 5.6).
Button Name
Stretching and
annealing unit
Opening the “Hot air zone” menu screen

• Tap the [Hot air zone] button
 The “Hot air zone” menu screen opens (see Chapter 5.5).
Button Name
Hot air zone

Resetting the switch-on duration

2. Tap the [Reset switch-on duration] button
 The switch-on duration is reset.

Reset switch-on
duration
5.8 "Trend" submenu
To open, tap the [Trend] button in the main menu
The measurement values for the production process are shown in this menu.
5.8.1 Diagram
Fig. 4499/5018
Actual values acc. to trend

1 3 Cursor 1 (red line)
setup
Timestamp of the cursor 4 Cursor 2 (blue line)
2
positions 5 [Move cursor] button

Representation of the measurement values

The diagram provides a graphical representation of measurement values from
the process.
The tables (1) show the current measurement values, as well as the
measurement values of two selected times, and the difference between them.
These times are defined by moving "Cursor 1" (3) and "Cursor 2" (4).
Changing the display period

2. Tap the [Change display period] button
 The diagram shows the selected display period.
Buttons Function Name
Reduce display period (zoom in)
Set the display period

to 8 hours
to 24 hours Change the display period

to 72 hours
Increase the display period
(zoom out)
Displaying / hiding the grid

 The [Trend setup] button is displayed hidden.
 The [Grid] button is displayed.
2. Tap the [Grid] button
 The grid is displayed or hidden according to the selection.
Green Displayed
Grid
Blue Hidden

Selecting the cursor

2. Tap the [Selected cursor] button
 The settings apply to Cursor 1 or 2, according to the selection
Button Colour Status Name
Blue Cursor 1 is selected

Selected cursor
Green Cursor 2 is selected
Moving the cursor

2. Tap the [Move cursor] button (5)
 This moves the cursor over the diagram to the left or to the right
according to the selection, along the x axis (time).

Arrow pointing
Move left
left
Move the cursor
Arrow pointing
Move right
right
Zooming the display area in or out

2. Tap the [Zoom] button
 This zooms the display area on the x axis (time) in or out according
to the selection.
Plus sign Zoom display area in

Zoom
Minus sign Zoom display area out

Moving the diagram along the x axis (time)

2. Tap the [Scroll x axis] button
 This moves the diagram to the left or to the right along the x axis
(time) according to the selection.

Arrow pointing
Move diagram left
left
Scroll x axis
Arrow pointing
Move diagram right
right
Moving the diagram along the y axis (production length)

2. Tap the [Scroll y axis] button
 This moves the diagram upwards or downwards along the y axis
(production length) according to the selection.

Arrow pointing
Move diagram up
up
Scroll y axis
Arrow pointing
Move diagram down
down
Opening the “Trend setup” menu screen

 The [Grid] button is hidden.
 The [Trend setup] button is displayed.
2. Tap the [Trend setup] button
 The “Trend setup” menu screen opens (see Chapter 5.8.2).
Trend setup

5.8.2 Trend setup
To open, tap the [Trend setup] button

in the “Trend” submenu,
This menu screen allows you to select the measurement values which should be
displayed on the "Diagram" menu screen (see Chapter 5.8.1) in the "Trend"
submenu.
Fig. 4499/5019
Selecting actual values displayed on the "Diagram" menu screen

1. Tap the selection list
 This displays the virtual navigation bar (see Chapter 4.2.3).
2. Select the desired actual value using the navigation bar
 The selected list entry is highlighted yellow.
 The selected actual value is displayed on the "Diagram" menu
screen (see Chapter 5.8.1)

5.9 "Report and recipe management" submenu
To open, tap the [Report and recipe management] button

in the main menu
This menu is used to generate reports and recipes and save them as a file.
5.9.1 Tabs
Fig. 4499/5020
Buttons Name / Function Buttons Name / Function
Production report Production report folder
Recipe system Recipes folder
Setup report Setup report folder
Move one item upwards Screenshots folder
Move one item

USB stick folder
downwards

Displaying data
2. Open the folder containing the file to be opened by tapping the relevant
button
3. Select the file in the folder by tapping the button [Move one item
upwards] or [Move one item downwards]
 The line of the selected file is highlighted yellow.
4. Tap the [Display data] button
 The "Display data" menu screen opens (see Chapter 5.9.2), and the
contents of the file is displayed.
Display data
Screenshots cannot be displayed on the control panel, though

they can be exported to a USB stick and then viewed on a
computer.
Sending a file by e-mail

2. Open the folder containing the file to be sent by tapping the relevant
button
4. Tap the [Send file by e-mail] button
 The file is sent by e-mail to the recipients listed in the fields
“e-mail address recipient 1 / 2” (see Chapter 4.5.3,
Fig. 4499/4008 (6)).
Send a file by e-mail

Importing a file
A file is imported from a USB stick onto the memory card as follows:
2. Connect the USB stick to the "USB1" port of the control panel (see the
manufacturer's documentation)
3. Open the folder by tapping the [USB stick folder] button
5. Tap the [Import file] button
 The file is saved to the controller's memory card.
 If a recipe is being imported:
The “Recipes” folder contains the imported file.
 If a text file is being imported:
The “Production report” folder contains the imported file.
Import a file
Exporting a file
A file is exported from the memory card onto a USB stick as follows:
3. Open the folder containing the file to be exported by tapping the
relevant button
5. Tap the [Export file] button
 The file is saved to the USB stick.
 The “USB stick” folder contains the exported file.
Export a file

Deleting an individual file

2. Open the folder containing the file to be deleted by tapping the relevant
button
4. Tap the [Delete file] button
 The file is irreversibly deleted.
Delete a file
Deleting all files in the folder

2. Open the folder containing the files to be deleted by tapping the relevant
button
3. Tap the [Delete all files] button
 All files in the folder are irreversibly deleted.
Delete all files

5.9.2 Displaying data
To open, tap the [Display data] button

in the “Report and recipe management” submenu,
This menu screen shows the contents of a file.
Fig. 4499/5021
1 Contents of the file 2 E-mail send status

5.9.3 Production report
To open, tap the [Production report] button

A production report consists of a list of process parameters (set and actual

values) and additional information which can be entered by the user to describe
the product and the production process in more detail. This menu screen is used
to generate the production report and save it to a file.
Fig. 4499/5022
1 Report name 8 Report preview

2 User name 9 Material name
3 Die gap Raw polymer MFI (melt flow
10
4 Distance from die to water index) / percentage
5 Filter tape 11 Type
6 Fibrillator setting Additive 1-4 name / percentage /
12 degree setting for volumetric
7 Comment dosing unit
Setting set values


Updating the report preview

• Tap the [Update report] button
 The report preview (8) is updated.
 The [Save report] button is displayed.
Update the report
Saving the report

1. Enter the report name (1), user name (2) and comment (7)
(see Chapter 4.4.1)
2. Update the report preview
3. Tap the [Save report] button
 The report is saved.
Save the report
5.9.4 Setup report
To open, tap the [Setup report] button

A setup report consists of a list of the plant settings and additional information
entered by the user. This menu screen is used to generate the setup report and
save it to a file.

Fig. 4499/5023
1 User name
3 Report preview
2 Comment
Setting set values

Updating the report preview

• Tap the [Update report] button
 The report preview (3) is updated.
 The [Save report] button is displayed.
Update the report
Saving the report

1. Enter the report name (1) and user name (2) (see Chapter 4.4.1)
2. Update the report preview
3. Tap the [Save report] button
 The report is saved.
Save the report

5.9.5 Recipe system 1/2
To open, tap the [Recipe system] button

in the “Report and recipe management” submenu, with
authorisation level 2 selected
A recipe consists of stored process parameters (set values). The recipe system is
used to save the controller's process parameters as a recipe file or to load them
from a recipe file into the controller. This menu screen is used to check and
modify the recipe values for the extruder.
Fig. 4499/5024
Die heating zone temperatures

1 4 Recipe name
(recipe value/actual)
Extruder heating zone
2 temperatures (recipe 5 [Save recipe] button
value/actual)
Extruder heating zone, intake 6 [YES] button
3 zone temperatures (recipe
value/actual) 7 Dialog window
The recipe can be saved and loaded from any menu screen in the
recipe system. This always loads or saves all the recipe values
from the two menu screens of the recipe system.
Setting recipe values


Creating a new recipe

As soon as all of the plant parameters have been set to allow the produced
product to achieve the desired quality, these can be saved as a new recipe as
follows:
1. Tap the [Transfer process values] button to transfer the current
parameters to the Recipe system
2. Enter a new name for the recipe in the input field
“Recipe name” (4) (see Chapter 4.4.1)
3. To create a recipe, tap the [Save recipe] button (5)
 The button colour changes during saving.
 This saves the control parameters as a new recipe.

Available for
Blue
selection
Accept process values
Process values are
Green
accepted
Loading a recipe
On opening a recipe, the process values are loaded from the file into the Recipe
system. If the recipe opened does not match the plant version or specification,
the loading process is interrupted and an error message is displayed. This
prevents the wrong process values from being loaded.
1. Select a recipe from the list (see Chapter 4.3.4)
 The line of the selected recipe is highlighted yellow.
2. To load a recipe, tap the [Load recipe] button
 The button colour changes during loading.
 The dialog window (7) is displayed, with the prompt asking whether
the recipe should really be loaded.
3. Tap the [YES] (6) button, to confirm the prompt
 This transfers the parameters from the controller as stipulated by the
recipe.
4. Configure the required mechanical settings
(see the starEX module manuals)

Available for
Red
selection
Load a recipe
Recipe values are
Green
accepted

5.9.6 Recipe system 2/2
To open, tap the [Recipe system 2/2] button

in the "Recipe system 1/2" menu screen
in the "Report and recipe management" submenu,
The recipe values of the hot air zone can be checked and modified on this menu
screen.
Fig. 4499/5025
Oil heating unit temperature

1 8 Interval (recipe value/actual)
(recipe value/actual)
Hot air zone temperature (recipe Take-down 1 speed (recipe
2 9
value/actual) value/actual)
Blower output (recipe
3 10 Elevation (recipe value/actual)
value/actual)
Cooling water temperature Water bath temperature (recipe
4 11
(recipe value/actual) value/actual)
Holding frame speed (recipe
5 Stretching / annealing (actual) 12
value/actual)
Line, finishing agent speed Fibrillator speed (actual) /
6 13
(recipe value/actual) stretching unit drive 1, 2
Take-down 2 (optional) speed Extruder speed (recipe
7 14
(recipe value/actual) value/actual)
Setting recipe values


Switching the oscillating knife bar on and off

This function has no effect on the current production run!
2. Tap the [Oscillating knife bar] button
 This activates or deactivates the oscillating knife bar in the recipe,

Green Active
Blue Not active
Opening the "Recipe system 1/2" menu screen

• Tap the [Recipe system 1/2] button
 The “Recipe system 1/2” menu screen opens (see Chapter 5.9.5).
Recipe system 1/2
5.10 “Information” submenu
To open, tap the [Information] button

in the main menu
This menu displays information on the different plant areas.

5.10.1 Bus information
Fig. 4499/5026
Pressure sensor CAN

1 Bus fault counter 8
connection status
Extruder drive CAN connection
2 X2X bus status 9
status
[Input/Output diagnostics 1/2]
3 [Control data] button 10
button
4 Status of CAN bus 11 [Drive information] button
Frequency converter CAN
5 [Extruder drive] button 12
connection status
6 [Pressure sensor] button 13 [Drive information] button
Dosing unit CAN connection Last message of the CAN open
7 14
status master
Activating and deactivating monitoring of the X2X bus modules

• Tap the [X2X bus monitoring] button
 This activates or deactivates X2X bus monitoring according to the
selection.
Green Active
X2X bus monitoring
Blue Not active

5.10.2 Input/Output diagnostics 1/2
To open, tap the

[Input/Output diagnostics 1/2] button
on the “Bus information” menu screen in the “Information” submenu,
The status of the I/O modules is displayed on this menu screen.
Fig. 4499/5027
1 Name of the I/O node 4 Module type

2 Module status 5 [Module selection] buttons
Current module diagnostics
3 Equipment identifier 6
program step (info)
Selecting an I/O node

The [Next] and [Back] buttons (see Chapter 4.3.3) can be used to scroll through
all the I/O nodes.
Module status

Green tick Module OK
Module error or
Red cross
module not present

Selecting I/O modules

• Tap the [Module selection] button
 Depending upon the status, the I/O module is selected (up to four
I/O modules at once) or deselected.
Green Selected
Module selection
Grey Deselected
Removing a module selection

• Tap the [Remove module selection] button
 No module is now selected.
Remove a module selection
Opening the “Input/Output diagnostics 2/2” menu screen

• Tap the [Input/Output diagnostics 2/2] button
 The “Input/Output diagnostics 2/2” menu screen opens (see
Chapter 5.10.3).
Input/Output diagnostics 2/2
Opening the "X2X bus modules serial numbers" menu screen

• Tap the [X2X bus modules serial numbers] button
 The “X2X bus modules serial numbers” menu screen opens (see
Chapter 5.10.4).
Button Name
X2X bus modules serial
numbers

5.10.3 Input/Output diagnostics 2/2
To open, tap the

[Input/Output diagnostics 2/2] button
on the “Input/Output diagnostics 1/2” menu screen
in the “Information” submenu,
Data for the I/O modules is displayed on this menu screen.
Fig. 4499/5028
Manually activating and deactivating inputs and outputs of I/O modules
NOTE!
Improper operation can cause damage to property.
It is vital that the instructions displayed on the control panel after
the [FORCE] button is pressed be followed!
• Tap the [FORCE] button

 A message containing further instructions is displayed.
Red Available for selection

FORCE
Green Message is displayed

5.10.4 X2X bus modules serial numbers
To open, tap the [X2X bus modules serial numbers] button

on the “Input/Output diagnostics 1/2” menu screen
in the “Information” submenu,
The serial numbers of the X2X bus modules are displayed on this menu screen.
Fig. 4499/5029
Exporting the data

2. Tap the [Export data] button
 The data is saved to the USB stick.

Available for
Blue
selection
Export the data
Data is being
Green
exported

5.10.5 Control data
To open, tap the [Control data] button

on the “Bus information” menu screen in the “Information”
submenu, with authorisation level 3 selected and additional
information displayed
This menu screen is used to display controller data, battery status and plant
operating hours.
Fig. 4499/5030
1 CPU information 4 IP address

2 Plant operating hours 5 Ping result
3 Battery status 6 Ethernet ping address
Battery status
The indicator (3) provides information about the status of the battery. If it is red,
the battery must be replaced (see Chapter 6.3).
Indicator Representation Meaning

Green bar Battery is OK
Red circle Change battery
Checking the network connection

1. Set the Ethernet ping address (6) (see Chapter 4.4.1)
2. Tap the [Ping] button
 The result of the test is displayed as the “Ping result” (5).

Ping
Opening the logbook

• Tap the [Logbook] button
 The “Logbook” menu screen opens (see Chapter 5.10.6).
Logbook
Displaying the variables

• Tap the [Variables] button
 The “Read / write variables” menu screen opens (see
Chapter 5.10.7).
Variables
Displaying hardware and software data

• Tap the [Hardware and software data] button
 The “Hardware and software data” menu screen opens (see Chapter
5.10.8).
Hardware and software data

5.10.6 Logbook
To open, tap the [Logbook] button

on the “Control data” menu screen in the “Information” submenu,
with authorisation level 3 selected and additional information
displayed
This menu screen displays the controller's logbook, allowing you to analyse
errors with the bus system and controller crashes.
Fig. 4499/5031
Exporting the data

2. Tap the [Update] button (see Chapter 4.3.4)
 The latest data is displayed.
3. Tap the [Export data] button
 The data is saved to the USB stick.

Available for
Blue
selection
Export the data
Data is being
Green
exported

5.10.7 Reading / writing variables
To open, tap the [Variables] button

on the “Control data” menu screen in the “Information” submenu,
displayed
This menu screen allows you to read variables. Writing may only be used under
the instruction of a Starlinger technician.
Fig. 4499/5032
1 Variable name 3 Value (set)

2 Value (actual) 4 Variable type
Setting set values

Transferring a value to a variable

• Tap the [Transfer value] button
 The set value is transferred to the variable.
Transfer value

5.10.8 Hardware and software data (System Diagnostics Manager)
To open, tap the [Hardware and software data] button on the

“Control data” menu screen in the “Information” submenu, with
authorisation level 3 selected and additional information displayed
This menu screen allows you to check the hardware and software data for the
controller.
Fig. 4499/5033
1 Tabs (can be selected by tapping)
Updating the displayed data

• Tap the [Update] button
 The data displayed is updated.
Update
Scrolling through the data

• Tap the [Scroll] button
 The data displayed scrolls up or down depending on which button is
selected.
Buttons Representation Process Meaning
Arrow pointing up Scroll up

Scroll
Arrow pointing down Scroll down

5.10.9 Drive information
To open, tap the [Drive information] button

with authorisation level 3 selected and additional information displayed
This menu screen shows information on the following drives:

• Take-down 1 / 2
• Holding frame
• Stretching unit
• Annealing unit
• Melt pump (optional)
• Fibrillator / precision fibrillator (optional)
• Finishing agent (optional)
Fig. 4499/5034
1 Main contactor status 10 Fault list, fault number, fault time

2 Ready status 11 Correction (actual)
3 Controller enable status 12 Set speed (actual)
4 CAN bus connection status 13 Actual speed (actual)
5 CAN bus address (actual) 14 Output frequency (actual)
Intermediate circuit voltage
6 Motor fan status 15
(actual)
Converter temperature (actual) /
7 Motor temperature status 16
status
8 Motor encoder status 17 Motor current / voltage (actual)
9 Operating time (actual) 18 Power on (actual)

Status of the digital inputs

Green bar ON
Red circle OFF
Exclamation mark Fault
Status of the motor temperature / motor encoder / converter temperature

Green tick OK
Red cross Fault
Updating the displayed data

• Tap the [Update] button
 The data displayed is updated.
Update
Resetting the fault

• Tap the [Reset fault] button
 The fault is reset.
Red Available for selection

Reset the fault
Green Faults are reset

5.10.10 Pressure sensor
To open, tap the [Pressure sensor] button

displayed
On this menu screen, all of the relevant parameters of the pressure sensors can
be checked and changed for the following pressure areas:
• before filter
• before pump
• before die
Fig. 4499/5035
1 Manufacturer 4 [Factory settings] button

2 CAN bus connection status 5 Parameter code digit (set/actual)
6 Parameter code digit (set)
3 [Zero point adjustment] button
7 Fault indicator (actual)
Setting set values


5.10.11 Extruder drive with frequency converter
To open, tap the [Extruder drive] button

This menu screen is only present on plants where the extruder drive is equipped
with a frequency converter; it shows data from this converter.
Fig. 4499/5036
Motor / rotor temperature

1 Status word (actual) 9
(actual)
2 Control word (actual) 10 Drive status
3 CAN connection status 11 Controller enable status
4 Converter temperature (actual) 12 Set speed (actual)
Actual speed acc. to
5 CAN in bits (actual) 13
speed sensor (actual)
Actual speed acc. to
6 CAN in words (actual) 14
frequency converter (actual)
7 CAN out bits (actual) 15 Motor current (actual)
Cooling water supply / return
8 CAN out words (actual) 16
(actual)
CAN connection / drive / controller enable status

Green bar OK
Red circle Fault

5.10.12 Extruder drive with DC controller
To open, tap the [Extruder drive] button

This menu screen is only present on plants where the extruder drive is equipped
with a DC controller; it shows data from this controller.
Fig. 4499/5037
1 Quick stop input status 10 Extruder on status

2 Pulse enable status 11 Screw speed (actual)
3 Controller enable status 12 Set speed on/off (actual)
4 Contactor on status 13 Bus counter (actual)
5 Converter status 14 Motor current (actual)
6 CAN bus connection status 15 Field current (actual)
Motor fan, carbon brushes,
7 16 Motor load (actual)
temperature status
8 Drive fault status 17 Drive fault number (actual)
9 Drive ready status 18 Status LEDs
Status (1-7), (9-10)

Green bar OK
Red circle Fault

Drive fault status

Green tick OK
Red cross Fault
5.11 “Maintenance” submenu
To open, tap the [Maintenance] button

in the main menu
This menu lists regularly performed maintenance tasks.
Fig. 4499/5038
Maintenance interval in Description of the specified

2
operating hours and remaining maintenance task
1
no. of O.H. until next
maintenance 3 Plant operating hours
NOTE!
The demanded maintenance work must be performed in order to
prevent damage to the plant. For more information on
maintenance, see the starEX module manuals.
The time in which the plant is not in operation, owing to

maintenance work, should be used to clean it.

Navigating lists
• Tap the [Navigation] button
 Depending upon the selection, the display moves one entry up or
down.
Buttons Representation Function Name / Function

Move one entry
Arrow pointing up
upwards
Navigation
Move one entry
Arrow pointing down
downwards
Localising the area of the plant to be maintained

When navigating the list (2), the area of the plant to be maintained is visually
highlighted (flashing red/yellow dots and dashes).
5.12 “Alarm management” submenu
To open, tap the [Alarm management] button

in the main menu
In this menu, you can check and reset alarms, as well as exporting them to a
USB stick if required.
5.12.1 Active alarms
Fig. 4499/5039
1 Alarm text 3 Alarm status

2 Alarm number 4 Time that alarm occurred

Alarm status

Arrow pointing up Incoming alarm
Arrow pointing down Outgoing alarm
Green circle Alarm acknowledged
Alarm procedure
All alarms which occur during operation are immediately displayed in the status
area (see Chapter 4.3.1, Fig. 4499/4005 (8)) in the form of alarms, and are
logged in the "Alarm management" screen. As soon as an operational condition
is re-established (for example, when the motor has reached a normal
temperature), the alarm disappears from the list of active alarms. However, it is
still visible in the Alarm history list (see Chapter 5.12.3).
Resetting an alarm
• Tap the [Reset alarm] button
 The alarm is reset
 The status symbol switches from yellow to green.
Reset an alarm
Displaying user actions

• Tap the [User actions] button
 The "User actions" menu screen (see Chapter 5.12.2) is displayed.
Button Name
User actions

Displaying event history

• Tap the [Event history] button
 The "Event history" menu screen (see Chapter 5.12.3) is displayed.
Button Name
Event history
5.12.2 User actions
To open, tap the [User actions] button

in the “Alarm management" submenu
All of the user actions (starting the plant, changing set values, etc.) are logged in
the User actions list. This is used to diagnose faults and monitor production.
User actions are displayed on this menu screen.
Fig. 4499/5040
1 Description of the action 3 Action status

2 Action number 4 Date and time that action

Displaying active alarms or the event history

• Tap the [Active alarms] or [Event history] button
 The "Active alarms" menu screen (see Chapter 5.12.1) or "Event
history" menu screen (see Chapter 5.12.3) is displayed.
Buttons Name
Active alarms
Event history
5.12.3 Event history
To open, tap the [Event history] button

in the “Alarm management” submenu
This menu screen displays alarms (events) that occurred in the past, and allows
you to export them onto a USB stick.
Fig. 4499/5041
1 Alarm text 3 Alarm status

Date and time that alarm
2 Alarm number 4
occurred

Alarm status

Arrow pointing up Incoming alarm
Arrow pointing down Outgoing alarm
Green circle Alarm acknowledged
Displaying active alarms

• Tap the [Active alarms] button
 The "Active alarms" menu screen (see Chapter 5.12.1) is displayed.
Button Name
Active alarms
Displaying user actions

• Tap the [User actions] button
 The "User actions" menu screen (see Chapter 5.12.2) is displayed.
Button Name
User actions
Filtering alarms
1. Tap the [Alarm type] button
 The list of alarm types opens.
2. Tap an alarm type in the list
 The list of alarm types closes and the list of alarms is filtered
depending on the alarm type selected.
Button Name
Alarm type

Exporting alarms
1. Connect the USB stick to the "USB1" port of the control panel
(see the manufacturer's documentation)
3. Tap the [Export alarms] button
 The alarms are saved to the USB stick.
Blue Available for selection

Export alarms
Green Alarms are being exported

5.13 Menu structure

Screenshots of all menu screens with chapter numbers and nesting:
5.1.1;00
Main menu
5.1.1
5.1.2;100
Calculations
5.1.2
4.5.1;200 4.5.3;201 4.5.4;210

Basic settings
4.5
4.5.5;212 4.5.5;211
4.5.5;213 4.5.5;214
4.5.1;0
6.1;221
6.2;0

Main menu 5.1.1;00

5.1.1
5.1.3;10
Dosing unit
5.1.3
5.1.4;85
Precision fibrillator
(optional)
5.1.4
5.1.5;84
Fibrillator (optional)
5.1.5
5.2.1;20 5.2.2;126
Extruder
5.2
5.3;30
Die
5.3
Water bath with take- 5.4.2;40 5.4.3;60

down and holding
frame
5.4
5.5.1;80 5.5.2;82
Hot air zone
5.5
Stretching and 5.6.1;90 5.6.2;90

annealing unit
5.6
5.7.1;170 5.7.2;171
Overview of heating
zones 5.7

5.1.1;00 5.10.1;111
Main menu 5.1 /
Information 5.10
5.10.2;120 5.10.3;129
5.10.4;116
5.10.5;112 5.10.6;115
5.10.7;250
5.10.8;240
5.10.9;118
5.10.10;12
5
5.10.11;11
3
5.10.12;11
4

Main menu 5.1.1;00

5.1
5.8.1;190 5.8.2;195
Trend
5.8
Report and recipe 5.9.1;130

management
5.9
5.9.2;139
5.9.3;131
5.9.4;135
5.9.5;132 5.9.6;133
5.11;180
Maintenance
5.11
5.12.1;140 5.12.2;150
Alarm management
5.12
5.12.3;145

6. MAINTENANCE
6 MAINTENANCE
The control panel is generally designed for low-maintenance operation.

Maintenance is limited to the following activities:
• Cleaning the touchscreen
• Calibrating the touchscreen
• Replacing hardware components
• Software updates
6.1 Cleaning the touchscreen

The control panel's touchscreen must be regularly cleaned with a suitable
cleaning agent and a lint-free cloth. Heavy dirt deposits must be removed
immediately.
CAUTION!
Malfunctions can be caused by accidentally triggering commands!
Only clean the touchscreen when the cleaning screen is selected
or when the unit is switched off!
NOTE!
The control panel may be damaged by improper cleaning!
Never spray cleaning agent directly onto the touchscreen!
Only use the following cleaning agents:
• Screen cleaner
• Alcohol
• Water and washing-up liquid

6. MAINTENANCE
Procedure for cleaning the touchscreen

1. Touch and hold the [Clean touchscreen] button for 3 seconds
 The cleaning screen is displayed:
Fig. 4499/6010
 While the cleaning screen is selected, it is not possible to perform

any user actions on screen.
2. Clean the touchscreen
 During the last 5 seconds of cleaning time, the following notice is
displayed:
Fig. 4499/6011
 After the cleaning time has elapsed, the main menu is displayed
automatically.
Clean the touchscreen
For more information on cleaning the touchscreen, see the manufacturer's

documentation.

6. MAINTENANCE
6.2 Calibrating the touchscreen
To open, tap the [Basic settings] button

in the main menu
and touch the [Calibrate touchscreen] button continuously

for 5 seconds in the “Basic settings” submenu
The touchscreen must be calibrated under the following conditions:

• After changing the memory card (see Chapter 6.4)
• If the location of the controls on the display does not match up with the
area which has to be tapped to activate them
Fig. 4499/6001
Calibration
• Tap the crosshairs which appear in the corners, one after another
 The touchscreen is calibrated.

6. MAINTENANCE
6.3 Changing the battery

The battery (4) must be changed if it is flat (see Chapter 6.4, Fig. 4499/6002).
This resets the set values to the factory settings. An alarm appears on screen.
For more information on changing the battery, see the manufacturer's
documentation.
6.4 Changing the memory card

The memory card contains the operating system and the control software as well
as all of the operating data (recipes, reports, etc.)
NOTE!
Risk of data loss!
Perform a backup of your data before changing the memory card!
CAUTION!
Risk of electric shock!
• Only change the memory card when the machine is de-
energised!
• Only change the memory card under the instruction of a
Starlinger technician!
Side and rear view of the control panel
Fig. 4499/6002
1 Ejector 3 Safety catch

2 Memory card 4 Battery

6. MAINTENANCE
Removing and replacing the memory card

1. Export recipes to the USB stick (see Chapter 5.9.1)
2. Note down the basic settings (see Chapter 4.5)
3. Move the <Main switch> to its OFF position
4. Open the cover on the control panel
 The memory card can be seen on the side of the control panel.
5. Pivot the safety catch (3) away
6. Push the ejector (1) (e.g. using a pen)
 The memory card (2) now protrudes slightly from the case.
7. Remove the memory card (2), taking note of its current orientation
8. If necessary, perform a software update (see Chapter 6.5)
9. Carefully push the new or updated memory card into the slot with the
correct orientation
10. Pivot the safety catch (3) over the card
11. Move the <Main switch> to its ON position
12. Check and if necessary readjust the basic settings (see Chapter 4.5)
13. Import recipes from the USB stick (see Chapter 5.9.1)
6.5 Software update
NOTE!
Risk of data loss!
Perform a backup of your data before updating the memory card!
To perform a software update, you will require the following:

• A computer with a USB port
• The PVI Transfer Tool software (see www.br-automation.com)
• A reader supporting CompactFlash memory cards
• A CompactFlash memory card (capacity to be specified by the
Starlinger technician)
• An update file with the extension .zp supplied by the Starlinger
technician
Fig. 4499/6003 – Example photo of a memory card in the reader

6. MAINTENANCE
Software update procedure

1. Remove the memory card (see Chapter 6.4, steps 1-8)
2. Insert the reader containing the removed or new memory card into the
USB port on the computer and launch the PVI Transfer Tool
 The main window of the PVI Transfer Tool opens.
Fig. 4499/6004
3. From the menus, select TOOLS  CREATE COMPACT FLASH…

or press <F9>
 The “Create Compact Flash” window opens.
Fig. 4499/6005
4. Click on the [Select disk] button

 The “Select disk” window opens.
Fig. 4499/6006

6. MAINTENANCE
5. Select the memory card from the list and click on the [OK] button
6. Click on the [Restore image] button
 The “Open” window opens.
Fig. 4499/6007
7. Select the update file and confirm by clicking the [Open] button
 A prompt appears asking if you wish to delete all the existing data on
the memory card and replace it with the data from the update file.
8. Confirm this prompt by clicking the [Yes] button
Fig. 4499/6008
 After the update is complete, a notification window appears.
Fig. 4499/6009
9. Close this window by clicking the [OK] button

 The software update is complete.
10. Insert the memory card (see Chapter 6.4, steps 9-13)

7. TROUBLESHOOTING
7 TROUBLESHOOTING
When contacting our Customer Service Center, please have the following
information to hand:
• The plant's serial number (machine number)
• General description of the problem
• Precise wording of the alarm text AND the alarm number,
as displayed in the Event history list (see Chapter 5.12.3)
• Fault codes shown on the screens for the affected drives
• As precise details as possible about when and under what
circumstances the fault occurred
• If you have already carried out tests, as precise details as possible
about the results obtained
• Name of the person familiar with the problem
• Your phone number and e-mail address
• The characteristics of a plant depend on the respective

customer's specifications.
• The following list of alarms may differ slightly depending on
customer requirements.
• All alarms can be viewed in the “Alarm management” menu
(see Chapter 5.12) on the display.
Composition of the alarm description

All alarms are described in Chapter 7.1 in table form, as illustrated in this
example:
Alarm number Alarm text

Cause Remedy / Description
Description of the possible cause(s) Procedure to rectify

7. TROUBLESHOOTING
7.1 Alarm group 00 – System alarms
00-000 Group acknowledgement

Cause Remedy
Status indicator See the manufacturer's documentation
00-001 Group bypassing

Cause Remedy
00-002 System initialised

Cause Remedy
00-003 Restarting the alarm printout

Cause Remedy
00-004 Printer not ready

Cause Remedy
Printer not ready for operation See the manufacturer's documentation
00-005 Alarm data cannot be read

Cause Remedy
Alarm data is not recognised See the manufacturer's documentation
00-006 Printer buffer overrun

Cause Remedy
Printer fault (buffer overrun) See the manufacturer's documentation
00-007 Battery flat

Cause Remedy
Control panel battery is flat Replace battery (see Chapter 6.3)

7. TROUBLESHOOTING
7.2 Alarm group 11 – Dosing unit
11-201 Dosing unit CAN connection fault

Cause Remedy
CAN bus connection fault See Chapter 7.19
11-202 Dosing unit has switched off! Suction time > 2h

Cause Remedy
Main components and hopper timeout .
Proximity switch reports "Fill level not See dosing unit technical manual
reached" for more than two hours
11-203 Dosing unit main material almost empty

Cause Remedy
• Check fill level
Too little main material in the dosing unit
• Top up main material
11-204 Large dosing unit mixture-hopper is empty

Cause Remedy
• Check fill level
Large mixture-hopper is empty
• Top up material
11-206 Dosing unit hopper cycle exceeded

Cause Remedy
Fill level in the extruder hopper not
See dosing unit technical manual
reached after three cycles
11-207 Dosing unit main components cycle exceeded

Cause Remedy
Fill level in the main components not
reached after three cycles
11-208 Dosing unit secondary component 1 cycle exceeded

Cause Remedy
Fill level in the secondary components 1
not reached after three cycles

7. TROUBLESHOOTING

Cause Remedy

Cause Remedy

Cause Remedy

Cause Remedy
11-401 Dosing unit vacuum pump 1 motor safety switch

Cause Remedy
Motor protection/thermal relay fault See Chapter 7.18
11-402 Dosing unit vacuum pump 2 motor safety switch

Cause Remedy
11-501 Dosing unit external fault

Cause Remedy
Fault in external alarm input Check external alarm input

7. TROUBLESHOOTING
7.3 Alarm group 12 – Extruder
12-200 CAUTION - hopper almost empty

Cause Remedy
There is too little main material in the
Check material feed in the dosing unit
hopper
Sensor fault See Chapter 7.23
12-201 Extruder empty

Cause Remedy
No material in the extruder Check material feed in the dosing unit
12-202 Extruder gearbox temperature ALARM {x}

Cause Remedy
• Check cooling system
Extruder gearbox temperature
• Check for noises
> 65°C
• Check oil change interval
12-203 Extruder gearbox temperature sensor break

Cause Remedy
12-204 Extruder infeed zone, excess temperature

Cause Remedy
Deviation from temperature tolerance See Chapter 7.22
12-205 Extruder infeed zone, sensor break

Cause Remedy
12-206 Line safety switch for heaters

Cause Remedy
• Check heating strip
The safety switch for the heaters has • Check heating circuit for short-circuit
tripped • Check connection cable
• Change fuse

7. TROUBLESHOOTING
12-210 Extruder insufficient temperature Z: {x}

Cause Remedy
12-211 Extruder excess temperature Z: {x}

Cause Remedy
12-212 Extruder sensor break Z:{x}

Cause Remedy
12-213 Extruder below min. tolerance

Cause Remedy
12-214 Extruder above max. tolerance

Cause Remedy
12-298 Extruder start not possible – temperature standby

Cause Remedy
Deactivate standby temperature
Standby temperature is activated
(see Chapter 5.2.1)
12-299 Extruder start not possible – check temp.

Cause Remedy
12-310 Extruder converter has no CAN connection

Cause Remedy
12-311 Extruder converter fault

Cause Remedy
Frequency converter fault See Chapter 7.16

7. TROUBLESHOOTING
12-312 Extruder converter overtemperature

Cause Remedy
12-330 Melt pump converter has no CAN connection

Cause Remedy
12-331 Melt pump converter fault

Cause Remedy
12-332 Melt pump converter overtemperature

Cause Remedy
12-400 Extruder motor overload

Cause Remedy
Motor has overheated See Chapter 7.17
12-401 Extruder motor speed too low

Cause Remedy
Motor sluggish or defective Check motor
12-420 Extruder motor fan

Cause Remedy
12-422 Extruder motor overtemperature

Cause Remedy

7. TROUBLESHOOTING
12-423 Extruder motor cooling water supply sensor break

Cause Remedy
12-424 Extruder motor cooling water return sensor break

Cause Remedy
12-425 Extruder motor cooling water flow rate too low

Cause Remedy
• Check cooling water temperature
The extruder drive is overheating. • Clean water strainer
• Check flow rate
12-426 Extruder motor rotor temperature sensor break

Cause Remedy
12-427 Extruder motor rotor temperature > {x}

Cause Remedy
12-432 Melt pump motor overtemperature

Cause Remedy
12-433 Melt pump motor encoder fault

Cause Remedy
Rotary encoder fault See Chapter 7.15
12-450 Extruder motor carbon brush fault

Cause Remedy
• Replace carbon brushes
Carbon brushes worn
• Clean interior area

7. TROUBLESHOOTING
12-500 Pressure before filter > {x} => line STOP!

Cause Remedy
• Check temperatures, melt and raw
material
Melt pressure in extruder over 400 bar
• Start the filter tape feed
(see Chapter 5.3)
12-501 Extruder cooling fan motor protection switch

Cause Remedy
12-510 Pressure before melt pump > {x} => line STOP!
Cause Remedy
Melt pressure in extruder before melt material
pump over 400 bar • Start the filter tape feed
(see Chapter 5.3)
12-520 Pressure before die > {x} => line STOP!

Cause Remedy
Melt pressure in extruder before die over material
400 bar • Start the filter tape feed
(see Chapter 5.3)
12-525 Pressure before die too low

Cause Remedy
Melt pressure in extruder before die too material
low • Start the filter tape feed
(see Chapter 5.3)

7. TROUBLESHOOTING
12-540 Pressure sensor before filter has no CAN connection

Cause Remedy
12-550 Pressure sensor before melt pump has no CAN connection

Cause Remedy
12-560 Pressure sensor before die has no CAN connection

Cause Remedy
12-570 Temperature {x} for filter feed within {x} not reached
Cause Remedy
• Check filter tape feed
The temperature for the filter tape feed
• Check heater fuse
was not reached in the specified time
• Increase time (see Chapter 5.3)
12-580 Extruder running gear fault

Cause Remedy
7.4 Alarm group 13 – Die
13-210 Die insufficient temperature

Cause Remedy
13-211 Die excess temperature

Cause Remedy
13-212 Die sensor break

Cause Remedy

7. TROUBLESHOOTING
13-213 Die below min. tolerance

Cause Remedy
13-214 Die above max. tolerance

Cause Remedy
13-220 Extruder insufficient temperature Z: {x}

Cause Remedy
13-221 Extruder excess temperature Z: {x}

Cause Remedy
13-222 Extruder tube sensor break

Cause Remedy
13-223 Extruder tube below min. tolerance

Cause Remedy
13-224 Extruder tube above max. tolerance

Cause Remedy
13-225 Die line safety switch for bolt heater

Cause Remedy
• Check heating strip
The safety switch for the heaters has • Check heating circuit for short-circuit
tripped • Check connection cable
• Change fuse

7. TROUBLESHOOTING
7.5 Alarm group 14 – Holding frame
14-100 Holding frame EMERGENCY STOP push button was pressed

Cause Remedy
Establish cause, unlock <EMERGENCY
EMERGENCY STOP active STOP> button and reset with <Reset
Emergency Stop> button
14-101 Holding frame EMERGENCY STOP pull cord

Cause Remedy
14-200 Water pump motor protection switch

Cause Remedy
14-201 Water exhauster motor protection switch

Cause Remedy
14-202 Water bath not in position

Cause Remedy
<Stop> push button fault See Chapter 7.20
14-203 Water bath overtemperature

Cause Remedy
14-205 Knife bar motor protection switch

Cause Remedy

7. TROUBLESHOOTING
14-206 Knife bar fault - check motor/sensor

Cause Remedy
14-240 Extruder Stop push button pushed or defective

Cause Remedy
14-241 Holding frame Stop button pushed or defective

Cause Remedy
14-310 FC take-down no CAN connection

Cause Remedy
14-311 FC take-down fault

Cause Remedy
14-312 FC take-down overtemperature

Cause Remedy
14-320 FC take-down 2 no CAN connection

Cause Remedy
14-321 FC take-down 2 fault

Cause Remedy

7. TROUBLESHOOTING
14-322 FC take-down 2 overtemperature

Cause Remedy
14-330 FC chill roll no CAN connection

Cause Remedy
14-331 FC chill roll fault

Cause Remedy
14-332 FC chill roll overtemperature

Cause Remedy
14-340 FC holding frame no CAN connection

Cause Remedy
14-341 FC holding frame fault

Cause Remedy
14-342 FC holding frame overtemperature

Cause Remedy
14-390 FC air knife no CAN connection

Cause Remedy
14-391 FC air knife fault

Cause Remedy

7. TROUBLESHOOTING
14-392 FC air knife overtemperature

Cause Remedy
14-412 Take-down motor overtemperature

Cause Remedy
14-413 Take-down motor encoder fault

Cause Remedy
14-422 Take-down 2 motor overtemperature

Cause Remedy
14-423 Take-down 2 motor encoder fault

Cause Remedy
14-432 Chill roll motor overtemperature

Cause Remedy
14-433 Chill roll motor encoder fault

Cause Remedy
14-442 Holding frame motor overtemperature

Cause Remedy
14-443 Holding frame motor encoder fault

Cause Remedy

7. TROUBLESHOOTING
14-492 Air knife motor overtemperature

Cause Remedy
14-501 Motor protection switch, edge strip recycling mill

Cause Remedy
14-502 Motor protection switch, edge strip recycling fan

Cause Remedy
14-503 Edge strip mill open

Cause Remedy
The cover of the edge strip mill is open Close the cover of the edge strip mill
14-504 Motor protection switch, holding frame tape exhauster

Cause Remedy
14-505 Holding frame heat exchanger fault

Cause Remedy
Temperature in switching cabinet > 65 °C See Chapter 7.21
14-506 Sand filter blocked

Cause Remedy
The sand filter is blocked Clean the sand filter
14-510 Edge strip recycling, screw drive fault

Cause Remedy
14-511 Motor protection switch, water pump NDC

Cause Remedy

7. TROUBLESHOOTING
14-512 Motor protection switch, air conditioner NDC

Cause Remedy
7.6 Alarm group 15 – Hot air zone
15-100 Oven EMERGENCY STOP push button pressed

Cause Remedy
15-110 Oil heating unit EMERGENCY STOP push button pressed

Cause Remedy
15-211 Oven overtemperature Z: {x}

Cause Remedy
15-212 Oven sensor break Z:{x}

Cause Remedy
15-213 Oven below min. tolerance

Cause Remedy
15-214 Over above max. tolerance

Cause Remedy
15-221 Oil heating unit overtemperature Z: {x}

Cause Remedy

7. TROUBLESHOOTING
15-222 Oil heating unit sensor break Z:{txsOelFuehlerbruch}

Cause Remedy
15-223 Oil heating unit below min. tolerance

Cause Remedy
15-224 Oil heating unit above max. tolerance

Cause Remedy
15-240 Oven Stop button pushed or defective

Cause Remedy
15-311 FC 1 oven fault

Cause Remedy
15-312 FC 2 oven fault

Cause Remedy
15-500 Oven heat exchanger fault

Cause Remedy
7.7 Alarm group 16 – Stretching unit
16-100 Stretching unit EMERGENCY STOP pull cord

Cause Remedy

7. TROUBLESHOOTING
16-110 Stretching unit EMERGENCY STOP push button pressed

Cause Remedy
16-150 Stretching frame safety cover open

Cause Remedy
The safety cover of the stretching frame is
open. Close safety cover
Plant stops in three minutes.
16-160 Add tape switch

Cause Remedy
<Add production run/tape> key switch
Turn <Add production run/tape> key
was turned clockwise. Plant stops in three
switch anticlockwise.
minutes.
16-200 Wrap-around monitor

Cause Remedy
• Stop the plant (see the starEX plant
A tape has become wound around a manual)
galette.
• Remove the tape from the galette
16-210 Stretching unit belt slipping

Cause Remedy
Max. belt slip correction reached > 10% Check belt
16-220 Stretching unit 2 belt slipping

Cause Remedy
Max. belt slip correction reached > 10% Check belt
16-240 Stretching unit Stop button pushed or defective

Cause Remedy

7. TROUBLESHOOTING
16-241 Stretching unit Line Stop button pushed or defective

Cause Remedy
16-242 Injector Stop button pushed or defective

Cause Remedy
16-243 Fibrillator Stop button pushed or defective

Cause Remedy
16-244 Tape exhauster Stop button pushed or defective

Cause Remedy
16-310 FC stretching unit no CAN connection

Cause Remedy
16-311 FC stretching unit fault

Cause Remedy
16-312 FC stretching unit overtemperature

Cause Remedy
• Check cooling system in switching
cabinet
Frequency converter has overheated
• See the manufacturer's
documentation
16-320 FC stretching unit 2 no CAN connection

Cause Remedy

7. TROUBLESHOOTING
16-321 FC stretching unit 2 fault

Cause Remedy
16-322 FC stretching unit 2 overtemperature

Cause Remedy
cabinet
documentation
16-350 FC fibrillator no CAN connection

Cause Remedy
16-351 FC fibrillator fault

Cause Remedy
16-352 FC fibrillator overtemperature

Cause Remedy
cabinet
documentation
16-355 FC Berger Lahr fibrillator no CAN connection

Cause Remedy
16-412 Stretching unit motor overtemperature

Cause Remedy
16-413 Stretching unit motor encoder fault

Cause Remedy

7. TROUBLESHOOTING
16-422 Stretching unit 2 motor overtemperature

Cause Remedy
16-423 Stretching unit 2 motor encoder fault

Cause Remedy
16-452 Fibrillator motor overtemperature

Cause Remedy
16-453 Fibrillator motor encoder fault

Cause Remedy
16-454 Berger Lahr fibrillator motor overloaded

Cause Remedy
16-455 Referencing of Berger Lahr fibrillator motor failed

Cause Remedy
The upper limit position was not reached Check lifting spindle for ease of
during the reference run movement
16-501 Stretching frame water pump motor protection switch

Cause Remedy
16-502 Tape oscillation fault

Cause Remedy
Check the mechanism and wiring of the
Motor stopped
motor

7. TROUBLESHOOTING
16-507 Fibrillator positioning motor motor protection switch

Cause Remedy
16-508 Fibrillator thread guide or coupler

Cause Remedy
Fibrillator is not locked Check position and locking of the fibrillator
16-509 Fibrillator servicing switch blocked

Cause Remedy
<Service / Operation> key switch was Turn <Service / Operation> key switch to
turned to position "0" position "1"
16-511 Fibrillator fan motor protection switch

Cause Remedy
16-512 Fibrillator exhauster motor protection switch

Cause Remedy
7.8 Alarm group 17 – Annealing unit
17-210 Annealing unit belt slipping

Cause Remedy
Max. belt slip correction reached >10% Check the size and condition of the belt
17-220 Annealing unit 2 belt slipping

Cause Remedy
Max. belt slip correction reached >10 % Check the size and condition of the belt

Cause Remedy

7. TROUBLESHOOTING

Cause Remedy
17-310 FC annealing unit no CAN connection

Cause Remedy
17-311 FC annealing unit fault

Cause Remedy
17-312 FC annealing unit overtemperature

Cause Remedy
cabinet
documentation
17-320 FC annealing unit 2 no CAN connection

Cause Remedy
17-321 FC annealing unit 2 fault

Cause Remedy
17-322 FC annealing unit 2 overtemperature

Cause Remedy
cabinet
documentation

Cause Remedy

7. TROUBLESHOOTING

Cause Remedy

Cause Remedy
cabinet
documentation

Cause Remedy

Cause Remedy

Cause Remedy
cabinet
documentation
17-390 FC finishing agent no CAN connection

Cause Remedy
17-391 FC finishing agent fault

Cause Remedy

7. TROUBLESHOOTING
17-392 FC finishing agent overtemperature

Cause Remedy
cabinet
documentation
17-412 Annealing unit motor overtemperature

Cause Remedy
17-413 Annealing unit motor encoder fault

Cause Remedy
17-422 Annealing unit 2 motor overtemperature

Cause Remedy
17-423 Annealing unit 2 motor encoder fault

Cause Remedy

Cause Remedy

Cause Remedy

Cause Remedy

7. TROUBLESHOOTING

Cause Remedy
17-492 Finishing agent motor overtemperature

Cause Remedy
17-504 Annealing unit tape exhauster motor protection switch

Cause Remedy
7.9 Alarm group 19 – General
19-000 EMERGENCY STOP active

Cause Remedy
19-056 Machine maintenance required

Cause Remedy
Carry out pending maintenance tasks
Maintenance interval reached
(see Chapter 5.11)
19-100 Bobbin winder EMERGENCY STOP push button pressed

Cause Remedy
19-111 Phase fault, phase 1: {x}

Cause Remedy
• Test fuse
Phase 1 has failed
• Check supply cable

7. TROUBLESHOOTING

Cause Remedy
• Test fuse
Phase 2 has failed

Cause Remedy
• Test fuse
Phase 3 has failed
19-206 X20 module fault: {x}

Cause Remedy
X2X bus connection faulty Check X2X bus connection
contact fault Check contact and wiring
Module faulty Check module and replace as necessary
19-207 X2X bus fault

Cause Remedy
X2X bus connection faulty Check X2X bus connection
19-300 Wait for drive system main contactor

Cause Remedy
EMERGENCY STOP has been reset 2x
Wait for period
within 3 min.
19-305 FC intermediate circuit voltage low

Cause Remedy
19-420 AC motor fan fault

Cause Remedy

7. TROUBLESHOOTING
19-500 Switching cabinet temperature > 65°C

Cause Remedy
19-501 Compressed air below 5 bar

Cause Remedy
• Incorrect setting on the pressure
regulator Check compressed air on maintenance
unit (see the starEX module manual)
• Customer's on-site supply is unstable
19-502 Switching cabinet sensor break

Cause Remedy
19-550 Chiller temperature too high

Cause Remedy
• Check cooling water temperature
• Clean water strainer
The cooling water supply temperature has
exceeded the set maximum value • Check flow rate
(see Chapter 4.5.5). • Check cooling unit (chiller)
(see the manufacturer's
documentation)
19-552 Cooling water sensor break

Cause Remedy
19-599 External fault

Cause Remedy
An external device is reporting a fault. Check the external device
19-999 FATAL ERROR! No USER PARTITION on the FLASH MEMORY

CARD
Cause Remedy
• Create new memory card (Starlinger
technician)
User partition does not exist
• Replace memory card
(see Chapter 6.4)

7. TROUBLESHOOTING
7.10 Alarm group 32 – Extruder warnings
32-200 Extruder speed limit

Cause Remedy
The extruder speed has exceeded the set
maximum value Check settings
32-202 Extruder gearbox temperature WARNING {txsExtrGetrTemp}

Cause Remedy
• Check cooling system
Extruder gearbox temperature
• Check for noises
> 65°C
• Check oil change interval
32-300 Extruder converter intermediate circuit voltage low

Cause Remedy
32-312 Extruder converter temperature > {x}

Cause Remedy
32-320 Extruder load > 90%

Cause Remedy
Utilisation of the extruder drive exceeds • Check temperatures
90%. • Reduce speed if necessary
32-420 Extruder motor temperature WARNING {x} – STOP at {x}

Cause Remedy
32-500 WARNING: pressure before filter > {x}

Cause Remedy
(see Chapter 5.3)
Melt pressure before filter > 350 bar • Check the temperature settings
• Check the melt
• Check raw material

7. TROUBLESHOOTING
32-510 WARNING: pressure before melt pump > {x}

Cause Remedy
(see Chapter 5.3)
Melt pressure before melt pump > 350 bar • Check the temperature settings
• Check the melt
32-520 WARNING: pressure before die > {x}

Cause Remedy
• Check the temperature settings
Melt pressure before die > 350 bar • Check the melt
32-530 WARNING: pressure before filter > {x}

Cause Remedy
(see Chapter 5.3)
The melt pressure before the filter is
exceeding the set warning pressure (see • Check the temperature settings
Chapter 5.3). • Check the melt
7.11 Alarm group 36 – Stretching frame warnings
36-100 Stretching frame safety cover open

Cause Remedy
The safety cover of the stretching frame is
open. Close safety cover
Plant stops in six minutes.
36-110 Tape attachment switch

Cause Remedy
<Add production run/tape> key switch
Turn <Add production run/tape> key
was turned clockwise. Plant stops in six
switch anticlockwise.
minutes.

7. TROUBLESHOOTING
7.12 Alarm group 39 – General warnings
39-100 WARNING: external supply voltage fault

Cause Remedy
• Check mains supply
Insufficient voltage or short-term failure • Measure the voltage with a meter and
record measurement
39-111 WARNING: voltage on phase 1 low: {x}

Cause Remedy
• Test fuse
Voltage on phase 1 is too low

Cause Remedy
• Test fuse

Cause Remedy
• Test fuse
39-200 Heater start timer active

Cause Remedy
Heater timer is active See Chapter 4.5.1
39-202 Standby temperatures

Cause Remedy
Deactivate standby temperature
Standby temperature is activated
(see Chapter 5.2.1)
39-210 Machine limit reached

Cause Remedy
At least one drive has reached the Check speeds for the drives and reduce if
maximum speed necessary

7. TROUBLESHOOTING
39-300 FC intermediate circuit voltage being checked

Cause Remedy
Check running Wait for check
39-305 FC intermediate circuit voltage low

Cause Remedy
39-500 Warning: switching cabinet temperature {x}

Cause Remedy
Temperature in switching cabinet > 55°C See Chapter 7.21
7.13 Alarm group 70 – File management
70-010 WARNING: file already exists

Cause Remedy
Assign a new name or delete the existing
File already exists
file
70-012 WARNING: max no. of files reached

Cause Remedy
Delete any files which are no longer
Max. possible number of files reached
needed
70-013 WARNING: prohibited input

Cause Remedy
Input not allowed Repeat input
70-014 WARNING: USB stick full, missing or write-protected

Cause Remedy
No USB stick inserted Insert USB stick
Delete any files off the USB stick, which
USB stick full
are no longer needed
Remove the USB stick, and then connect
USB stick not recognised by the system
it again
Remove the write-protection on the USB
USB stick is write-protected
stick

7. TROUBLESHOOTING
7.14 Alarm group 59 – Operating messages
59-001 Machine started

59-002 Machine stopped
59-010 Order 1 is ready
59-011 Order 2 is ready
59-201 Extruder started
59-202 Extruder stopped
59-221 Material: PP
59-222 Material: HDPE
59-401 Holding frame started
59-402 Holding frame stopped
59-601 Stretching frame started
59-602 Stretching frame stopped
59-901 General heaters ON
59-902 General heaters OFF
59-903 Heater start timer enabled
7.15 Rotary encoder fault

In the event of a rotary encoder fault, the following steps must be taken one after
the other until the problem has been solved:
1. Press the <Fault reset> button on the control panel
2. Check the cable connections of the rotary encoder
3. Disconnect and reconnect plugged connections
(only in a de-energised state!)
4. Press the <EMERGENCY STOP> button
5. Replace the motor
6. Replace the cable of the rotary encoder
7. Set control type "1" on the menu screen of the drive in question

7. TROUBLESHOOTING
Setting the control type

If a fault occurs on the encoder of one of the 3~AC motors driven by the
frequency converters, this is displayed on the Alarm management screen (see
Chapter 5.12). At the same time, a safety function prevents the speed of the
motor from continuously increasing.
If the defect cannot be rectified or the encoder replaced due to a lack of the
relevant spare part, the affected drive can be switched to slip compensation until
the spare part arrives. Once this measure is performed, production can return to
full swing.
If the belt is slipping due to the load or because of wear, this is compensated for
automatically by belt slip correction. This involves a sensor measuring the actual
speed of the godet, which is then corrected accordingly.
The following control types can be set on the menu screen of the respective
drive:
• 0 = PID (proportional integral derivative)
The drive is controlled by the rotary encoder on the motor.
• 1 = SLP (slip compensation)
The drive is controlled by slip compensation in the frequency converter.
• 2 = EPC (electronic process control)
The drive is controlled by the rotary encoder on the motor and by belt
slip correction.
• 3 = STP (step speed control)
The drive is controlled by slip compensation in the frequency converter
and belt slip correction.
• The encoder must be replaced quickly, because the affected

drive will run less precisely with slip compensation.
• Until the encoder is replaced, slip compensation must be
reactivated after every machine stop.
• If a drive does not support the selected drive type,
the last-selected drive type is chosen automatically.

7. TROUBLESHOOTING
7.16 Frequency converter fault

If a frequency converter is not ready, the following steps must be taken one after
the other until the problem has been solved:
1. Tap the [Reset alarm] button (see Chapter 5.12.1)
 This activates the reset input on the frequency converter.
2. Check power supply:
- Check the mains supply and the mains fuses
- Check the supply motor protection
3. Look-up the fault displayed on the frequency converter in the
manufacturer's documentation
4. Move the <Main switch> to its OFF position
5. Wait 30 seconds
6. Move the <Main switch> to its ON position
7. Perform the following measurements:
- Input voltage
- Set value specification for speed
- Signal for enable forwards/backwards
- Ready for operation signal
- Signal mode
- Signal fault
- Actual current value output
- Output voltage to the motor
8. Check connection cables
9. Compare programming
10. Check terminal connections for tight fit (also on the motor terminal
board)
11. Check the motor for short-circuit/short-circuit to earth and other
malfunctions
12. Replace the frequency converter if faults persist

7. TROUBLESHOOTING
7.17 Motor overheating

If a motor overheats, proceed as follows:
1. Allow motor to cool down
2. Check if the fan cover is dirty
3. Check that the fan blades are intact
4. Check the mechanism
5. Check if the ambient temperature is too high
6. Check the machine parameters
7.18 Motor protection/thermal relay fault

If the motor protection has tripped, proceed as follows:
• Compare set current value on the triggering device with the value on the
motor type plate
• Check mains supply
• Check motor temperature
• Check terminal connections for tight fit (also on the motor terminal
board)
• Check motor for ease of movement (bearings)
• Heed the direction of rotation
• Check the lines to the motor (short circuit and earth)
• Measure voltage/current
7.19 CAN bus connection fault

In the event faults with the CAN bus connection, proceed as follows:
• Restart the plant
- Switch the plant off
- Wait 30 seconds
- Switch the plant on
• Check CAN addressing (node switch or parameter)
• Check CAN cable connection and measure resistance
• Check terminating resistors
(2 x 120 Ohm, i.e. 60 Ohm total on the cable)
• Check shielding

7. TROUBLESHOOTING
7.20 <Stop> push button fault

This alarm may be caused by the following:
• <Stop> push button was held down in the respective area for longer
than 30 s
• Cable break in the Stop loop or fault in the machine wiring
• <Stop> push button is defective
In order to rectify these, proceed as follows:

• Check the contact of the <Stop> push button in the respective area
• Inspect the wiring of the Stop loop (see circuit diagrams)
• Replace the <Stop> push button
7.21 Overheating of the switching cabinet

A cooling system is built in to prevent overheating of the switching cabinet. If the
temperature in the switching cabinet rises above 55°C, proceed as follows:
• Close the switching cabinet door
(the heat exchanger is not operational with the door open)
• Open the cooling water line
• If necessary, increase the flow volume on the water distributor
• Inspect the cooling unit, if necessary adjust the set temperature (set
value = 35°C)
• Check the differential pressure
• Check if the supply temperature at the cooling unit intake is too high
• Clean the filter in the cooling line
• Inspect the fan in the switching cabinet and replace if necessary
• Inspect the valve in the cooling unit and replace if necessary
• Reduce the ambient temperature
7.22 Deviation from temperature tolerance

If the temperature is above or below the set tolerance limit, proceed as follows:
• Check temperature settings of the extruder (see Chapter 5.2.1)
• Check heater
- Check fuses and proper functioning of the contactors/solid state
relay
- Check heating elements with an ammeter or ohmmeter

7. TROUBLESHOOTING
• Check thermocouple (see Chapter 7.23.2)

• Check cooling circuit
- Medium
- Pump
- Three-way valve
• Adjust cooling circuit
During the heating phase, insufficient temperatures are not a

definitive indicator of a fault.
7.23 Sensor fault

The different types of sensors are described in this chapter. It also provides
information on how sensors are set and checked.
7.23.1 Proximity switch

Inductive proximity switches (e.g. end position sensors) trigger a signal when
approached by metal objects (e.g. aluminium, brass or steel), while capacitive
proximity switches (e.g. fill level sensors) trigger a signal when approached by
non-metal materials (e.g. plastic, glass or liquids).
The strength and quality of the signal depends on the wiring and on the
positioning of the sensor. If the sensor is set correctly but does not switch
properly, it is faulty.
If a proximity switch does not function, the following steps must be taken:
1. Check whether the surface of the sensor is damaged (e.g. scratches or
dents)
2. Check and as necessary tighten terminal connections
3. Check and as necessary replace cables
4. Check sensor position and reposition if necessary
5. Replace sensors if these are faulty
 If the new sensor does not function, the control is faulty.
Checking the sensor position

Every sensor has a given detection area which is reduced by half with steel,
aluminium or brass.
Trigger the sensor with a suitable object and check the PLC input in accordance
with the circuit diagram. All the outputs and inputs are also listed in the display.

7. TROUBLESHOOTING
The optimal setting is always in the lower half of the output value:
• M8: max. s=2mm
• M12: max. s=4mm
Positioning the sensor

1. Unplug connector
2. Undo nut (sensor is freed)
3. Set the distance between the sensor and the object with a feeler gauge
4. Check the connector
5. Tighten nuts with a spanner
7.23.2 Checking the thermocouple

The thermocouples are used to measure temperatures. There are versions that
are potted (e.g. in the extruder zone) and those with a connecting head. If a
thermocouple does not function, the following steps must be taken:
dents)
2. Check and tighten terminal connections where required, observe
polarity:
- Red, black, green, orange, purple = PLUS
- Blue, white = MINUS
4. For sensors with a connecting head,
- disconnect and twist the connection line
 The ambient temperature is displayed on the screen:
The sensor is faulty.
 The ambient temperature is not displayed on the screen:
The control input is faulty.
5. For potted sensors:
- Connect a new sensor or a twisted compensating line to the control
 The ambient temperature is displayed on the screen:
The sensor is faulty.
 The ambient temperature is not displayed on the screen:
The control input is faulty.
6. Replace the sensor if it is faulty (do not use cable end sleeves!)

7. TROUBLESHOOTING
7.23.3 Pressure sensor

If a pressure sensor does not function, the following steps must be taken:
dents)
2. Check and as necessary tighten terminal connections
4. Measure the supply voltage and the output signals
5. Replace sensors if these are faulty

8. ENCLOSURES
NOTES
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DBE-04499Deng - Display

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USER MANUAL

Doc. no.: DBE-04499D Language: English

Warranty and liability

starEX Display DBE-04499D PAGE 2 / 163

ABOUT THIS DOCUMENT............................................................................................... 7

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5.1.3 "Dosing unit" submenu.............................................................................. 34

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5.10.9 Drive information....................................................................................... 99

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7.23 Sensor fault..................................................................................................... 160

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ABOUT THIS DOCUMENT

Notation Representation Example

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Indicator word Meaning

Immediately hazardous situation which will lead to death or

Potentially hazardous situation, which may lead to death or

Potentially hazardous situation, which may lead to minor or

Possible damage to property which may occur if the safety

Terms and abbreviations

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1.2 Ambient conditions

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2 COMPONENTS AND INTERFACES

2.1 Communications interfaces

Ethernet X2X bus Control panel

Holding frame Hot air zone

Take-down Stretching frame

Melt pump (optional)

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2.2 Control panel

Malfunctions or damage to property due to faults resulting from

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3 CONTROL AND DISPLAY COMPONENTS

3.1 Control panel

3.2 User interface

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4 BASIC INFORMATION ON OPERATION

4.1 Readiness for operation

Graphical user interface

• The graphical user interface is dynamic and reflects the

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4.1.2 Switching off

4.2 Virtual input devices

4.2.1 Virtual keypad

1 Valid range for the input value 2 Input value

Delete input value

Cancel input and close virtual keypad

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4.2.2 Virtual keyboard

Delete input value

Cancel input and close virtual keyboard

4.2.3 Virtual navigation bar

- Close navigation bar

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4.3 Layout of the graphical user interface

1 Status area 2 Working area

4.3.1 Status area

Selected authorisation level

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"Menu number" indicator / [Screenshot] button

Button Colour Status Name / Function

If authorisation level 0 or 1 is selected (see Chapter 4.5.2), the [Authorisation