HOW TO NAVIGATE THE HMI

The Main Page provides access to the following features:

1.- Machine Type: This section indicates whether your machine is configured as a CSF model (Single Servo System) or a CSD model (Dual Servo System).

2.- Total Box Count: This section displays the total number of boxes the machine has processed over its lifetime.

3.- DAS Status: It will indicate whether the DAS feature is enabled or disabled on the machine.

4.- Box Width Category: It will display the category of the last box processed by the machine, determined by its width and assigned a value from 1 to 6.

5.- Replace Top Tape (CSD Only): If the machine is in Manual Mode and in an inactive state (not running or ready to receive boxes), a “MOVE” option will appear. Pressing and holding this option for more than 3 seconds will lower the Sealing Area completely, allowing improved access to the top tape head.

6.- User Login: Enables access to system configuration settings after successful login.

LOGIN PAGE

On the Login Page, two user profiles will be available: one designated for BestPack personnel and another for Supervisors. As the machine owner, you are expected to access the system using the Supervisor profile. Select the Supervisor account and input the corresponding password when prompted. The default password is “1234”.

Once the password is entered, press "Enter." A new button labeled “Main Menu” will become visible in the lower right corner of the screen. Use this menu to access and adjust the machine’s configuration settings.

MAIN MENU PAGE

The Main Menu includes the following options:

• Manual Mode: Allows manual activation of key outputs, such as motors and cylinders, for functional testing.
• Parameter Settings: Provides access to machine configuration parameters. You can adjust operational timers and define the positions of the Folding and Sealing Areas based on the box size being processed.
• Alarm History: Displays the current alarm status in the event of a jam and allows review of previous fault messages in the alarm history log.
• DAS: If the DAS option is enabled on the unit, you can access this section to view key metrics such as IDLE TIME, RUN TIME, and DOWN TIME.
• Operation Log: Records access to the HMI configuration pages, including user identity, date, and time of access.
• Start-Up Page: Returns the user to the initial home screen.

MANUAL MODE

To engage any of the manual control functions, begin by switching the machine to Manual Mode using the Auto/Manual selector switch located on the operator panel. Make sure the machine is not currently operating or processing boxes. To confirm this, press the Stop button, then press Reset to bring the system to a safe and idle condition.

Once the system is confirmed to be in Manual Mode and inactive, you can initiate any of the manual operations. Each function is clearly identified on the left side of the interface, indicating the specific actuator or output that will be triggered when selected.

ALARM HISTORY PAGE

The active alarm will be shown on the Alarm Main Page. If no message is displayed, it means there are no current faults on the machine.

In the event of a fault, the red light on the machine’s stack light will begin flashing, and a message detailing the active fault will appear on the same screen. This feature is designed to help you quickly identify the issue, enabling faster and more efficient troubleshooting.

By selecting the Alarm History option located in the bottom right corner, you can view the machine's fault history from the past week. This feature is particularly useful for reviewing issues that occurred during a specific shift, as it records both the fault type and the exact timestamp of each event.

OPERATION LOG PAGE

The Operation Log page provides detailed records of all HMI configuration logins at fixed time intervals (hourly and daily). Each log entry includes the user ID, timestamp, and actions performed, enabling a comprehensive audit trail and real-time monitoring of system access and configuration changes.

START-UP PAGE

Selecting the “START-UP PAGE” option will simultaneously log out the current user and redirect the screen to the initial startup page. A QR code will be displayed on this screen, providing additional information related to your unit.

PARAMETER SETTINGS

In the Parameter Settings section, a menu is displayed with multiple options. Each option corresponds to a specific group of settings, enabling the operator to review the current values and, if required, modify them.

NOTE: If your CSF/CSD machine is equipped with a MicroLogix 1400 PLC, all delay timer values are expressed in centiseconds (cs), where:

• 1 cs = 0.01 seconds

If the machine is equipped with a Micro850 PLC, all delay timer values are expressed in milliseconds (ms), where:

• 1 ms = 0.001 seconds

It is important to verify the PLC platform installed on the machine before reviewing or modifying timer parameters, as the same numerical value will represent different time intervals depending on the controller being used. Incorrect interpretation of the timer units may result in improper machine operation or unexpected system behavior.

Interlock Controls

These parameters allow you to configure the timing interlocks between the infeed and outfeed conveyors. Properly setting the upstream and downstream parameters is critical for ensuring reliable automation, preventing product handling issues, and maintaining a smooth production flow.

• INFEED CONVEYOR STOP DELAY (Factory Settings: 250 ms): When the Indexer entry photo-eye detects a box entering the machine, this timer is initiated. After the configured delay expires, the infeed conveyor stops to prevent a double-feed condition and ensure proper product spacing.

• INFEED CONVEYOR START DELAY (Factory Settings: 50 ms): After the current box has been measured and transferred to the Folding Area, the start delay timer begins. Once the timer completes, the infeed conveyor is reactivated, allowing the next box to enter the machine in a controlled manner.

• DOWNSTREAM CONVEYOR DELAY FOR PAUSE (Factory Settings: 200 ms): If a downstream sensor is connected, this parameter defines how long the sensor must detect a product before the machine is paused. Once the downstream area is clear, the machine automatically resumes operation.

Indexer Parameters

As the first section of the machine, the Indexer contains the following configurable timers. All values are displayed in milliseconds (ms) and can be adjusted as required:

• IND CENTERING ARM RELEASE (Factory Settings: 1400 ms): Controls the activation of the centering arms, which hold the box at the machine entry. This ensures the box is positioned at the center of the Indexer while measurements are taken.
• CARTON SPACING TIMER (Factory Settings: 0 ms): Defines the delay used to create spacing between boxes during back-to-back testing inside the machine.
• INDEXER RAISE COMPLETE DELAY (Factory Settings: 0 ms): Maintains the Indexer in the raised position while the box passes through the next section of the machine (Folding Area).
• INDEXER DROP DELAY TON (Factory Settings: 0 ms): Determines the delay before lowering the Indexer to receive the next box. The timer begins once the box clears the Indexer Exit Photo-Eye.
• UPSTREAM STOP IN TON (Factory Settings: 0 ms): Sets the interlock delay with the infeed conveyor (external system). This is the time allowed for the conveyor to stop after the Indexer Entry Photo-Eye detects a box, preventing double-feeding into the machine.
• UPSTREAM EARLY IN TON (Factory Settings: 0 ms): Sets the interlock delay with the infeed conveyor (external system). This is the time before the conveyor reactivates to send the next box to the Indexer.

Folding Parameters

As the second section of the machine, the Folding Area includes the following configurable values:

• FOLDING AREA HEIGHT DISTANCE – MAX (Factory Setting: 545 mm): Defines the maximum allowable height of the Folding Area. Any closed box exceeding this dimension will not be compatible with the machine.
• FOLDING AREA HEIGHT DISTANCE – MIN (Factory Setting: 135 mm): Defines the minimum allowable height of the Folding Area. Any closed box below this dimension will not be compatible with the machine.
• FOLDING AREA HEIGHT DISTANCE – OFFSET (Factory Setting: 25 mm): Applies an additional offset to the box height measurement. This prevents the box from being positioned too close to the scoreline and avoids issues with overfilled boxes.
• FOLDING AREA RELEASE SIDE BELT DRIVE EARLY – TON (Factory Setting: 300 ms): Sets the timer that resets the side belts of the Folding Area when the box passes the Folding Area Exit Photo-Eye.
• MOVE FA TO MIN POSITION: When the machine is in Manual Mode, pressing this button moves the Folding Area to its lowest position.

Sealing Parameters

The Sealing Area includes the following configurable values:

• SEALING AREA HEIGHT DISTANCE – MAX (Factory Setting: 585 mm): Defines the maximum allowable height of the Sealing Area. Any closed box exceeding this dimension will not be compatible with the machine. Option compatible with CSD only.
• SEALING AREA HEIGHT DISTANCE – MIN (Factory Setting: 120 mm): Defines the minimum allowable height of the Sealing Area. Any closed box below this dimension will not be compatible with the machine. Option compatible with CSD only.
• SEALING AREA HEIGHT DISTANCE – OFFSET (Factory Setting: 30 mm): Applies an additional offset to the box height measurement. This prevents the box from being positioned too close to the top and avoids jamming or damage to the major flaps. Option compatible with CSD only.
• SEALING AREA HEIGHT FLOAT MOVE [CSD] (Factory Setting: 10 mm): When the Sealing Area Float is activated, this value adjusts the Mast position slightly lower (or higher, if greater than the original offset) to align more closely with the box top and improve tape application. Option compatible with CSD only.
• SEALING AREA HEIGHT FLOAT START TON [CSD] (Factory Setting: 250 ms): Determines the delay before float activation is triggered once the box enters the Sealing Area. Option compatible with CSD only.
• MOVE SA TO MIN POSITION: When the machine is in Manual Mode, pressing this button moves the Sealing Area to its lowest position. Option compatible with CSD only.
• SEALING AREA INCH IT FORWARD TON (Factory Setting: 0 ms): Defines the delay to move the box slightly forward before the Sealing Area Mast lowers.

Height Analog Settings

This section provides calibration parameters and real-time measurement information for the height sensor:

• HEIGHT OFFSET: Adds an additional offset to the Actual Measured in mm value.
• RANGE OF ANALOG SENSOR: Calibration parameter for the analog sensor. If the Actual Measured in mm value is inaccurate, adjust this setting.
• ANALOG MEASURED RAW: Displays the real-time raw sensor value of the box or object detected by the height sensor.
• ACTUAL MEASURED IN MM: Displays the real-time measured height of the box or object in millimeters (mm).

Carton Judge

The Carton Judge displays the width of the most recently processed box. Based on this measurement, the system assigns the corresponding box category.

This section is for information display only. No parameters can be adjusted.

Rear Minor Timers

The Rear Minor Timers control the cylinder that actuates the kicker, moving it up and down to fold the rear flap. Depending on the box width, a Box Category is assigned, and the system classifies each box as either Short or Long:

• Short Box: Detected only by the Indexer Exit Photo-Eye while the Indexer centering arms hold the box for measurement.
• Long Box: Detected by both the Indexer Entry Photo-Eye and the Indexer Exit Photo-Eye while the Indexer centering arms hold the box for measurement.

CATEGORY/WIDTH Display

On the HMI, the CATEGORY/WIDTH section provides the following information:

• Left side: The category of the previously processed box.
• Center: The length classification of the box (0 = Short Box, 1 = Long Box).
• Right side: The timer value (in milliseconds) assigned to that specific box.

If the Rear Flap Folder (Kicker) is activating too early or too late and fails to fold the flap correctly, the corresponding timer can be manually adjusted. Using the information displayed on the HMI, the operator can identify and fine-tune the specific timer required.

Width Analog Settings

This section provides calibration parameters and real-time measurement information for the width sensor:

• NARROW ARM IN MM (Factory Setting: 105 mm): Defines the minimum allowable box width. Any closed box below this dimension will not be compatible with the machine.
• NARROW ARM IN ANALOG: Defines the minimum allowable width as a raw sensor value. This parameter updates automatically when Narrow Arm in mm is adjusted.
• WIDE ARM IN MM (Factory Setting: 535 mm): Defines the maximum allowable box width. Any closed box exceeding this dimension will not be compatible with the machine.
• WIDE ARM IN ANALOG: Defines the maximum allowable width as a raw sensor value. This parameter updates automatically when Wide Arm in mm is adjusted.
• ANALOG MEASURED RAW: Displays the real-time raw sensor value of the box detected by the width sensor.
• ACTUAL MEASURED IN MM: Displays the real-time measured width of the box in millimeters (mm).

Box Configuration

Box categories are defined by the width of the box. On the Box Configuration page, the range values that determine each category are displayed.

The CURRENT CATEGORY field shows the category assigned to the most recently processed box.

Major Flap Timers

The Major Flap Timers control the cylinders that fold the side flaps. If the Major Flap Folders activate too early or too late and fail to fold the flaps correctly, the corresponding timer can be manually adjusted. Using the information displayed on the HMI, the operator can identify and fine-tune the specific timer required.

Box Classification: Depending on the box width, a Box Category is assigned, and the system classifies each box as either Short or Long:

• Short Box: Detected only by the Indexer Exit Photo-Eye while the Indexer centering arms hold the box for measurement.
• Long Box: Detected by both the Indexer Entry Photo-Eye and the Indexer Exit Photo-Eye while the Indexer centering arms hold the box for measurement.

Inch it Forward

This section is particularly useful for CSF units when processing small boxes that may not reach the Sealing Area (SA) paddle switch before it begins its downward movement.

Depending on the box dimensions, a delay can be configured before the Sealing Area mast starts its descent. This additional time allows the box to travel far enough into the sealing area to be properly detected and captured by the SA system before the sealing cycle begins.

In most applications, these timer values remain set to 0 seconds. However, they may need to be adjusted based on the specific box sizes and operating conditions at the customer's site to ensure reliable product handling and proper sealing operation.

CATEGORY/WIDTH Display

On the HMI, the CATEGORY/WIDTH section provides the following information:

• Left side: The category of the previously processed box.
• Center: The length classification of the box (0 = Short Box, 1 = Long Box).
• Right side: The timer value (in milliseconds) assigned to that specific box.

LTNT Parameters

The LTNT Parameters page of the HMI contains tape monitoring functions and related settings that are applied during the sealing process.

• BOX TRAILING EDGE TO TH REAR ROLLER (Factory Setting: 300 ms): Defines the delay before activating the Wipe Delay feature, which improves the tape finishing process.
• WIPE DELAY MOTOR STOP (Factory Setting: 500 ms): Determines the duration that the Sealing Area side belt motors stop as part of the Wipe Delay feature. Once the timer expires, the motors resume operation.
• START NO TAPE CHECK (Factory Setting: 500 ms): Sets the delay before verifying whether the tape has been correctly applied to the box.
• TOP TAPE MONITORING & BOTTOM TAPE MONITORING: Enables or disables monitoring of the top or bottom tape application.

ON: The machine detects faults and stops if boxes are sent without tape or if the top or bottom Tape Head fails to cut the tape.

OFF: The machine ignores tape-related faults on the top side.

• SA TOP ROLLER START (Factory Setting: 300 ms): Defines the delay before activating the Top Compression Rollers when a box enters the Sealing Area.
• SA TOP ROLLER RELEASE (Factory Setting: 300 ms): Defines the duration of Top Compression Roller engagement once the signal is triggered. When the timer expires, the machine retracts the Top Compression Rollers outward.

Depth Configuration

If the machine is equipped with an ultrasonic sensor for bypass box detection, the parameters in this section can be configured to define the bypass conditions and verify the criteria required for a box to be classified as a bypass product.

• Bypass (Sensor & Measurement Limit): This parameter enables or disables the bypass feature when an ultrasonic sensor is installed. The ultrasonic sensor measures the depth of incoming boxes and provides one method for determining bypass conditions. Additionally, a height-based bypass threshold can be configured. If a box height is below the specified measurement limit, the machine will automatically classify the box as a bypass box and process it accordingly.

• Bypass Through Measurement Limit Only: When this option is enabled, the machine ignores the ultrasonic sensor measurement and relies exclusively on the configured measurement limit. Any box with a height below the specified threshold will be automatically classified as a bypass box.

• Measurement Limit in mm (Bypass if the box height is less than): This parameter defines the maximum box height that qualifies for bypass operation. Any box with a measured height below this value will be identified as a bypass box

• BOX HEIGHT FROM ULTRASONIC SENSOR (Offset) in MM: This parameter applies an offset to the measurement obtained from the ultrasonic sensor. The offset can be used to compensate for installation tolerances or sensor positioning and improve measurement accuracy.

• HEIGHT FROM TIP OF THE SENSOR TO BED ROLLER in MM: This parameter defines the physical distance between the face of the ultrasonic sensor and the indexer bed rollers. This value is used as part of the height calculation process and should be measured accurately during machine setup.

• Subtract (Left Side) / Add (Right Side) in mm for Source B: This parameter allows a tolerance to be applied to Source B, which is the height value measured by the ultrasonic sensor.

  Source A = Height value obtained from the analog height sensor.

  Source B = Height value obtained from the ultrasonic sensor.

  The configured value can be used to either add to or subtract from the Source B measurement, allowing fine adjustment of the comparison between both measurement sources. This tolerance helps determine whether the conditions required to classify a box as a bypass product have been met.

Machine Configuration

The HMI program is compatible with both CSF and CSD models. However, the correct machine type must be selected prior to operation. Once the correct machine model is selected, the system will function properly.

If the current MACHINE TYPE setting is not compatible with the installed model, update the configuration as follows:

1. Click the Machine Type Selector on the HMI.

   

2. Choose the machine type that matches the installed model.
3. The selected value is stored in the machine’s memory and will be retained even after a power cycle.