Operation of Machine
7. Operation of Machine (HMI Screens)
1.Instructions
1.1 Operator Duties.
The Operator will:
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Maintain an overview of the entire machine.
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Monitor machine performance and investigate any alarms that occur and resolve or call maintenance.
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Ensure all the mechanical setpoints (Hard_Variables) are correctly set to their values.
1.2 HMI Navigation
Every page on the HMI has the same Top Banner on it.
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Press to navigate to the Main Control Screen.
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Displays the current logged in User
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Press to navigate to the Overview Screen.
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Press to navigate to the Safety screen.
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Displays an Active Alarms popup. Press to navigate to the Alarm Page
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Press to navigate to the Interface Screen.
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Press to navigate to the Menu screen.
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Press to navigate to the User Management Screen.
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Alarm Acknowledge button.
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1.3 Control Buttons
Operational Control Buttons on RML Machines use symbols that comply with the IEC-60417 standard. The colours do not comply with any standard, however we have implemented industry standards as a guideline.
Reference and Symbol
IEC Title
BRML Title
IEC Function
BRML Function
IEC 60417-5008
“OFF” (Power)
“Off”
(Not Ready for Safety Reset)
To indicate disconnection from the mains, at least for mains switches or their positions, and all those cases where safety is involved.
To indicate the machine is De-Energized and that there is a safety device preventing the machine from being Powered ON
IEC 60417-5009
Standby
Reset
To identify the switch or switch position by means of which part of the equipment is switched on in order to bring it into the Standby condition.
To indicate the machine is powered on but requires a Reset to bring it to an Idle State.
IEC 60417-5011
“ON/OFF” (Push button)
“Off”
(Ready for Safety Reset)
To indicate connection to the mains, at least for mains switches or their positions, and all those cases where safety is involved. "OFF" is a stable position, whilst the "ON" position only remains during the time the button is de-pressed.
To indicate the machine is De-Energized and that it is in a state where it can be powered ON
IEC 60417-5104
Start
Start
To identify the Start Button.
To identify the Start Button.
IEC 60417-5110A
Stop
Stop
To identify the control or the indicator to stop the active function.
To identify the Stop Button. Stop will terminate all Sequences immediately, bringing the machine to a Rapid Stop.
IEC 60417-5111A
Pause, interruption
Hold
To identify the control or the indicator which stops operation intermittently and keeps the equipment in Operating Mode.
To identify the Hold Button. Hold will transition the machine to a Held State, allowing all the sequences to complete their current function
1.4 Side Control Bar
The Side Control Bar provides access to common machine functions. I.e., Start, Stop and Off buttons may be accessed from any display.
Pressing the RML logo in the Top Banner opens and closes the Side Control Bar.
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1. Start Push Button - Press to issue a start command to the machine. When in the Execute state, this button will change to the Hold icon.
2. Stop Push Button - Press to terminate all sequences immediately, bringing the machine to a rapid stop.
3. Off (Not Ready for Safety Reset) Push Button - This is shown when the machine is in the Aborted state and the E-Stop is pressed. When the E-Stop is released, the icon becomes the Off – Ready for Safety Reset button. If the machine enters the Stopped state, the icon becomes the Reset button.
4. Machine Home Button - Press to home the machine.
5. ABB Home Button - Press to Home the Robot.
6. Batch Complete Button - Press to Complete The Batch.
7. IRB Robot Batch Complete Button - Press to Complete The IRB Robot Batch.
1.5 HMI Main Control Screen
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Machine State Model. Displays the current State of the Machine
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Machine Status Bar. Provides information on the current machine state
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Machine Home Button is pressed to home the machine or reset all of the Sequences back to Step 0.
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Machine Statistics: Press to launch the dedicated Statistics Display.
1.6 Machine State Control
PackML Machine State Model has been implemented for the overall control of this machine. There are three machine state types that define the current condition of the machine:
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Acting State – represents a processing activity, i.e., Aborting, Clearing, Stopping, Resetting Un-holding, Holding, Un-Suspend, Suspending and Completing.
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Wait State – identifies that a machine has achieved a defined set of conditions, i.e., Aborted, Stopped, Idle, Held, Suspended and Completed.
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Dual State – a Wait State that is causing the machine to appear as an Acting State. There is only one Dual State: Execute.
The image above shows the 17 Machine States and transition paths between states. The operator uses the control buttons on the main overview page to transition from state to state.
PackML Machine State Model States
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Aborting: An E-Stop has been pressed or a door has been opened while in a running or Holding state. All power and air is being removed from the zone. The machine will be brought to a rapid, controlled, safe stop.
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Aborted: All power and air have been removed from the zone. The machine maintains relevant information about the abort condition. A Safety Reset command will force a transition to the Clearing state.
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Clearing: The machine is to clear faults that may have occurred when aborting and that are present in the Aborted state before proceeding to a Stopped state.
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Stopping: The machine executes a controlled and safe stop.
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Stopped: Machine is powered and stationary.
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Resetting: The machine enters an energized state awaiting a start command. The machine will be homed in this state if necessary.
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Idle: Machine resetting is complete and ready to start up.
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Starting: Machines perform steps required to enter the Execute state.
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Execute: The machine is operating and producing product.
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Holding: The machine is being brought to a controlled stop when executing.
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Held: The machine is paused either by the operator or a fault occurs in the Execute state.
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Un-Holding: The machine is being prepared to re-enter the Execute state.
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Suspending: Machine is being prepared to enter the suspended state.
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Suspended: The machine enters this state due to a request from out/in-feed.
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Un-suspending: The Machine is being prepared to re-enter the Execute state.
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Completing: Machine has run product to completion. Used at the end of a production run to drain any remaining product from all machines within this zone. I.e., processing of the product at the infeed will stop.
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Complete: The machine is waiting for a stop command that will bring the machine into the stopped state.
Restart after an Emergency Stop or Monitored Guard being opened
Check the machine to see if the reason for the E-Stop activation or guard door opening has been cleared.
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If an E-Stop was activated, release all E-Stop buttons (Twist to release)
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If a guard door was opened, close any guard doors that are open.
Once the E-Stop has been released and guard doors are closed, press the RESET button on the Side Control Bar or Main Control Display. This will reset the safety system and bring the machine into the idle state.
1.7 Machine Restart from Held or Suspended State
From Machine Fault:
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Check machine fault
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Carry out necessary actions to resolve the fault
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Once the fault has been cleared, press the START button on the Side Control Bar or Main Control Display.
From Line Fault:
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Check line fault
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Carry out necessary actions to resolve the fault.
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Once the fault has been cleared, the machine should automatically restart.
Ensure the safety system is reset, Press the Start push button on the Side Control Bar to start the machine
2. Menu Layout and Screens
2.1 Main Menu
Press the buttons on the menu screen to open the particular screen.
Maintenance info: Press to launch the manual, electrical drawing, pneumatic drawing, Layout, Sensor Manual, and Pressure Switch Manual
2.2 User Login
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1. Enter username
2. Enter Password
3. Click to Login
4. Click to Logout
5. Click to Change Password
Following is a matrix of the level access for each user, please note the Level 1-4 passwords are able to be altered for customer preference.
Level 5 are set aside for RML Engineering access only to enable machine setup.
2.3 User Management
User Creation/Deletion
Refer the below steps to create the new User ID
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1. Press the Create button to add a new user.
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Enter the name of the new user
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Enter the user's password. The password must comply with the password policy
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Click the Apply button to save the new user.
Refer the below steps to delete the User ID
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1. Select the user to be deleted.
2. Click on the delete button to delete the user.
2.4 Mimic - Overview Display
The Overview Display provides an overview of the machine layout. Specific areas of the machine can be navigated to by using the Arrow buttons.
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1. Pressing this button in the navigation panel will launch the Mimic Overview Screen. This can be accessed from a display on the HMI
2. These icons around the display will launch the Mimic indicated in the Arrow box when pressed. E.g. pressing the “IRB Robot” button will launch a mimic for that area of the machine.Press on Sub-assembly area for manual operation for Example: -solenoid valve, motor, photo eye etc.…
2.5 Mimic Overview – Device Legend
2.6 Mimic - Safety Screen
The Safety Mimic provides an overview of the machine. The safety devices are shown in their approximate locations around the machine and have the following color indication.
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Green is ready for Reset.
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Grey is Open.
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Red is in Fault.
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1. This area displays Safety Devices that are in the Main Control cabinet or are in fields mounted on the machine.
2. This is an indicator for an Estop Switch.
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Green is Closed
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Grey is Open
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Red is in Fault.
Pressing this Icon will launch a face plate for this device.
3. This is an indicator for a Door Switch..
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Green is Released
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Grey is Pressed
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Red is in Fault.
Pressing this Icon will launch a face plate for this device.
2.7 Mimic – Machine Module
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1. Device Indicator. These are.
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Green when on or running.
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Grey when off
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Red when in fault.
Pressing a device icon will launch a popup for that object.
2.8 Sequences
Clicking on the Sequences button in the Menu launches this display.
Example: -
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1. Sequence Status. This displays the Sequence Name, Current Step and description of the current action that is taking place. 2. Pressing this button launches another faceplate with more detail on that Sequence. That faceplate can be seen below.
2.9 Interface
1. Input: It indicates the Digital Input
2. Output: It indiactes the Digital Outputs.
3. LED Indication:
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Red: It indicates the Alarm in the System.
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Green: It indicates the system is in Idle state.
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Amber: It indicates the system is in Alert State.
2.10 Current Alarms
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Current Alarms: Current Alarm screen shows the current alarms that are active and can be access through the Menu Screen (as mentioned in 2.1), or by clicking in the Top bar (as mentioned in 1.2)
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TimeStamp: The date and time when the alarm has occurred.
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Name: Alarm name.
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SourceName: Refers to the type or source of the alarm.
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Message: The current alarm message to be displayed on the page
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Active: Indicates the current state of the alarm (Active/Inactive).
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Acknowledge: Used to acknowledge the alarm once the issue is resolved.
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Severity: Indicates the priority level of the alarm:
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Severity 1 – Urgent (High Priority)
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Severity 2 – Less Urgent (Medium Priority)
2.11 Alarm History
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Alarm History: Alarm History screen shows the record of alarm that have occured in the past and can be access through the Menu Screen (as mentioned in 2.1).
1. ConditionName: Shows the Condition name for that particular alarm
2. SourceName: Shows the source name for that particular alarm
3. Message: Message displayed for that alarm
4. Severity: The severity rate for that alarm (Severity 1 and 2, where severity 1 being the highest)
5. DateTime: The Date and time when thaat particular alarm occured
2.12 Tracking List
2.13 I/O List
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1. Remote I/O Name: Displays the name of the Remote I/O module.
2. Device Status Indicator:
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Green: When ON or Running
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Grey: When OFF
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Red: When in Fault
3.Change Remote I/O: Option to switch or navigate to the next Remote I/O module.
3. Face Plates
3.1 Mimic – Device Legend
3.2 Cylinder
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Tag name and description for the selected cylinder.
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Number of times the cylinder has been actuated.
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Cylinder status flags showing Output State, Reed Status, Alarm and Manual state.
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Timer pre-sets for the cylinder alarms. If the cylinder is setup as having no reed switches, these timers become extend and retract times for the cylinder.
3.3 Miscellaneous Input
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Tag name and description for the selected device.
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Current status of the device with de-bounce times applied
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Device Status
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De-bounce and Fault Times.
3.4 Miscellaneous Output
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Tag name and description for the selected device.
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Current State of the device.
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Current Status of the device.
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Fault timer and cycle counter.
3.5 Servo Motor
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Tag name and description for the selected servo.
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Display Velocity and Position feedback and position Setpoint.
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Current drive status
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Pressing here will launch the servo settings display.
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Pressing here will launch a home selection screen. This will provide information about the homing of the axis.
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Manual Controls. You must be logged in as a technician to gain access to these controls.
3.7 Servo Setting
This display is launched from the servo faceplate and show the setpoints for the servo control. You must be logged in as a technician to gain access to these controls.
3.8 Service
4. Stack Light Indication
4.1 Green Stack Light
4.2 Amber Stack Light
4.3 Red Stack Light
SOP (Standard Operation Procedure)
1. SOP for Startup
1.1 Power On the system:
1. Power on the Main Control Panel and ON CP0301and ensure CP0302 control panel is also ON.
2. Ensure there is no emergency stop push button pressed and all Guard doors are closed.
3. Ensure that the Robot Pendant Switch is in OFF Mode and Controller is in Auto Mode
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Auto
1.2 Start the system:
1. Press the safety reset button to energize the system.
Safety Rest
2. Do Home to load appropriate recipe.
Select Home
Select Yes
Rest
3. After Home Done start the System.
Select Start