Printing Rollflex

USER MANUAL
Display
rollFLEX PX6
roll printing machine
Doc. no.: DBE- 04967 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 owner failing to
adhere to the intended use.
rollFLEX PX6 display DBE-04967 PAGE 2 / 153

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

1 AREA OF APPLICATION ........................................................................................... 10
1.1 Function .............................................................................................................. 10
1.2 Ambient conditions ............................................................................................. 10
2 COMPONENTS AND INTERFACES .......................................................................... 11
2.1 Communications interfaces ................................................................................ 11
2.2 Control panel ...................................................................................................... 11
2.3 Software.............................................................................................................. 11
3 CONTROLS AND DISPLAY ELEMENTS ................................................................... 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 the submenus ........................................................................... 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 winder emergency operation .................................... 27
4.5.4 Machine settings ........................................................................................ 30
4.5.5 Fabric course of travel for the print variant ................................................. 31
4.5.6 Factory settings .......................................................................................... 32
5 WORKING WITH THE PROGRAM............................................................................. 33
5.1 Main menu .......................................................................................................... 33
5.2 "Unwinder" submenu .......................................................................................... 35

TABLE OF CONTENTS
5.3 “Corona pre-treatment unit” submenu ................................................................ 38

5.3.1 Status and control of the corona pre-treatment unit ................................... 38
5.3.2 Fault and status messages ........................................................................ 39
5.4 “Infeed” submenu................................................................................................ 41
5.5 “Print” submenu .................................................................................................. 43
5.5.1 Print overview ............................................................................................. 43
5.5.2 Printing unit ................................................................................................ 44
5.5.3 Servo drives ............................................................................................... 48
5.6 "Drying system" submenu................................................................................... 49
5.7 "Discharge" submenu ......................................................................................... 51
5.8 "Winder" submenu .............................................................................................. 54
5.8.1 Status and control of the machine area...................................................... 55
5.8.2 Winder diagnostics ..................................................................................... 58
5.8.3 Shift statistics ............................................................................................. 63
5.8.4 Advanced winding mode ............................................................................ 63
5.9 “Report and recipe management" submenu ....................................................... 65
5.9.1 Overview .................................................................................................... 65
5.9.2 Displaying data ........................................................................................... 68
5.9.3 Production report ........................................................................................ 69
5.9.4 Setup report................................................................................................ 71
5.9.5 Safety system report .................................................................................. 72
5.10 “Information” submenu........................................................................................ 73
5.10.1 Control unit ................................................................................................. 73
5.10.2 Control unit logbook ................................................................................... 75
5.10.3 Hardware and software data ...................................................................... 76
5.10.4 Communications interfaces ........................................................................ 77
5.10.5 Safety control ............................................................................................. 78
5.10.6 Safety control logbook ................................................................................ 79
5.10.7 Alarm history of the frequency converter .................................................... 80
5.11 “Alarm management” submenu .......................................................................... 81
5.11.1 Active alarms .............................................................................................. 82
5.11.2 User actions ............................................................................................... 83
5.11.3 Alarm history .............................................................................................. 84
5.12 Menu structure .................................................................................................... 87
6 MAINTENANCE .......................................................................................................... 90
6.1 Cleaning the touchscreen ................................................................................... 90
6.2 Calibrating the touchscreen ................................................................................ 92
6.3 Changing the battery .......................................................................................... 93

TABLE OF CONTENTS
6.4 Changing the memory card ................................................................................ 93

6.5 Software update.................................................................................................. 94
7 TROUBLESHOOTING ................................................................................................ 95
7.1 Alarm group 00 - System alarms ........................................................................ 96
7.2 Alarm group 02 - Servo controller ....................................................................... 96
7.3 Alarm group 03 - Drives .................................................................................... 106
7.4 Alarm group 04 - Unwinder ............................................................................... 107
7.5 Alarm group 08 - Winder................................................................................... 113
7.6 Alarm group 12 - Corona .................................................................................. 117
7.7 Alarm group 19 - General 1 .............................................................................. 120
7.8 Alarm group 20 - General 2 .............................................................................. 124
7.9 Alarm group 59 - Operating messages ............................................................. 127
7.10 Alarm group 70 - File management .................................................................. 127
7.11 Bus systems ..................................................................................................... 128
7.11.1 Checking the X2X link bus ....................................................................... 128
7.11.2 Checking the EPL bus connection (POWERLINK ethernet) .................... 130
7.12 Sensors ............................................................................................................ 131
7.12.1 Checking proximity switches .................................................................... 131
7.12.2 Checking the pressure sensor.................................................................. 132
7.12.3 Checking the thermocouple...................................................................... 132
7.12.4 Checking the light sensor ......................................................................... 134
7.12.5 Checking the light barrier ......................................................................... 134
7.13 Switching cabinet air conditioning..................................................................... 135
7.13.1 Inspecting the switching cabinet with fan ................................................. 135
7.13.2 Inspecting the switching cabinet with heat exchanger ............................. 135
7.14 DC drives .......................................................................................................... 136
7.14.1 Checking the DC drive for overheating .................................................... 136
7.14.2 Determining the cause that triggered the motor protection ...................... 137
7.14.3 Checking the frequency converter............................................................ 137
7.15 Stepper motors ................................................................................................. 138
7.15.1 Checking a stepper motor after overheating ............................................ 138
7.15.2 Checking the stepper motor module ........................................................ 138
7.15.3 Stepper motor module is referenced incorrectly....................................... 139
7.16 Servo drives ...................................................................................................... 139
7.16.1 Checking the servo converter for overheating.......................................... 139
7.16.2 Checking the servo motor for overheating ............................................... 139
7.16.3 Checking the servo converter.................................................................. 140
7.16.4 Checking the servo motor ........................................................................ 140
7.16.5 Checking the servo converter for a phase failure ..................................... 140

TABLE OF CONTENTS
7.16.6 Checking the rotary encoder .................................................................... 141

7.16.7 Checking for a lag error ............................................................................ 141
7.17 Fault in the safety system ................................................................................. 142
7.17.1 Checking safety control X20SL8000 ........................................................ 142
7.17.2 Checking the safety switch ....................................................................... 149
7.17.3 Checking for partial actuation of the safety door circuit............................ 150
7.17.4 Checking for a cross-circuit in the safety door circuit ............................... 150
7.17.5 Checking the earth or short-circuit of a pulse output ................................ 150
7.18 Machine-specific tests ...................................................................................... 151
7.18.1 Checking the <Stop> push button ............................................................ 151
7.18.2 Checking the web edge control ................................................................ 151
7.18.3 Print mark error ........................................................................................ 151
7.18.4 Limit position fault..................................................................................... 152
7.18.5 Checking the control voltage .................................................................... 152

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 rollFLEX PX6 roll printing machine. This
documentation series comprises the following documents:
• General safety instructions
• Technical manual
• 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, servicing and
maintenance of the machine. It contains all of the information needed to work on
or with the machine safely and properly and must therefore be observed
precisely. Compliance with the stated instructions and guidelines will also
increase the service life and optimise the performance of the machine.
NOTE!
The documentation series must always be at hand where the
machine is used and must be read and used by everyone who
works on or with the machine.
Notation
This document uses the following notation:
Notation Representation Example

Reference Italics See the Layout plan
Name, Dialog text Quotation marks “Basic settings” submenu
(Push) button, switch Angle brackets <Stop>
Button Square brackets [Cancel]

ABOUT THIS DOCUMENT
Multi-step instructions
In this document, multi-step instructions are presented as follows:
1. Step 1
2. Step 2
- Subtask
3. Step 3
 Result
Lists
In this document, lists are presented as follows:
• List item 1
• List item 2
- Sub-item / Subtask
• List item 3
 Result
Steps which do not have a particular defined order are also presented in the form
of lists. In such cases, the lists may have subtasks and results.
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

ABOUT THIS DOCUMENT
Pictograms
This document contains pictograms with the following meaning:
General warning: risk of injury
General notice: potential damage to property
Important information
Reference to further information
Terms and abbreviations

In this document, the rollFLEX PX6 roll printing machine is referred to in short as
"the machine", and set and actual values as "set" and "actual". The operating
side of the machine is abbreviated to "OS", and the drive side to "DS". All other
important abbreviations are explained within the document.
Figures
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 rollFLEX PX6 roll
printing machine. It consists of a control panel with a touch-sensitive screen
(touchscreen), the corresponding software with a graphical user interface and a
programmable control unit 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 individual components
• Control parts of the machine manually
• Confirm alarms
• Report and recipe management
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 Customer
Control unit
network
X2X or ethernet
POWERLINK
Bus coupling
I/O modules
Sensors /
Actuators
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 unit.
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. CONTROLS AND DISPLAY ELEMENTS
3 CONTROLS AND DISPLAY ELEMENTS
3.1 Control panel
For a detailed description of all the control and display elements

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
Switching the machine on (see the rollFLEX PX6 technical manual) automatically
puts the control panel into operation.
Starting up the control panel comprises the following steps:
1. Boot process
2. Loading of the operating system
3. Launching of the control software
Graphical user interface

The graphical user interface main menu appears and the control panel is ready
about 60 s after being switched on.
The main menu is the starting point for all actions by the user, and serves as an
overview of key parameters of the machine:
Fig. 4967/4001
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 (see the rollFLEX PX6 technical 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. 4967/4002
1 Valid range for the input value 2 Input value
Button 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. 4967/4003
Button 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 and enables the
navigation and selection of list entries.
Button Function
Jump to the first / last entry
Jump to the first / last visible entry
Scroll upwards / downwards
Not assigned
Highlight entry
Close navigation bar

ON OPERATION
4.3 Layout of the graphical user interface

The graphical user interface is broken down into two areas:
Fig. 4967/4004
1 Status area 2 Working area
4.3.1 Status area

The status area (1) is permanently displayed, and consists of the following
controls:
Fig. 4967/4005
Selected authorisation level

1 [Additional information] button 5 indicator and [Basic settings]
button
Status indicator and
2 6 Date and time
button [Main menu]
Menu number indicator and
Machine type indicator and
3 7 [Screenshot] or [Authorisation
status indicator
level 2] button
[Alarm management]
4 [Basic settings] button 8
indicator and button

ON OPERATION
“Alarm management” indicator

The "Alarm management" indicator (8) shows the active alarm and also serves as
a button. Tapping it opens the "Alarm management" submenu (see Chapter
5.11).
“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).
"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 secs
 The appearance of the button changes while you are touching it and
when the screenshot is being saved to the “Screenshots” folder in
the “Report and recipe management” submenu (see Chapter 5.9).
Button Representation Status Name / Function
Ready to take
Blue
screenshot
Button is being
Yellow Screenshot
touched
Screenshot is
Green
being saved
If authorisation level 0 or 1 is selected, the [Authorisation level 2] button (see

Chapter 4.5.2) is displayed instead of the [Screenshot] button.
Button Name / Function
Authorisation level 2

ON OPERATION
Displaying / hiding additional information

• Tap the [Additional information] button
 The button changes depending on the state.
 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
4.3.2 Working area

The working area (see Chapter 4.3, Fig. 4967/4004 (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 the submenus

The following buttons are used to navigate submenus:
Button Name Function
Scroll forward one menu

Forward
page
Scroll back one menu

Back
page
4.3.4 Navigating lists

The following buttons are used to navigate lists:
Button Name Function
Move one entry upwards /

Upwards / Downwards
downwards
Update Update the displayed data

ON OPERATION
4.3.5 Calculator
Many menu screens have a calculator, which is opened as follows:
• Tap the [Calculator] button
 The calculator opens.
Calculator
4.3.6 Screensaver
The screensaver is displayed automatically when the control panel has not being
used for a period of 30 min.
Fig. 4967/4006
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. 4967/4001) 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:
Example Representation Field type Field contents
Input field
White/Black Set value
with/without focus
Blue Display field Set value calculated
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. 4967/4002).
 In alphanumeric input fields:
This opens the virtual keyboard
(see Chapter 4.2.2, Fig. 4967/4003).
2. Enter the 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
Sunken Active
Raised Not active
Precise information on the individual buttons can be found in the description for
the respective menu.

ON OPERATION
4.5 Basic settings
4.5.1 “Basic settings” submenu
To open, tap the [Basic settings] button

in the main menu
In this menu, you can modify the basic settings.
Fig. 4967/4007
1 Selected language 7 [Fabric course of travel] button

2 Screen brightness 8 Shift number
3 Password entry field 9 Start of shift
4 Display of the date and time 10 End of shift
5 Enter date and time 11 Shift duration
6 Print variant status 12 Active shift
Print variant status
Appearance Representation Status
Green tick Selected
No symbol Deselected

ON OPERATION
Setting the print variant

• Tap the [Print variant] button
 The "Print variant" status (6) changes accordingly.
 Depending on the selection, the front of the fabric is printed
with 3 - 6 colours, and the back with 0 - 3 colours.
Print variant
The fabric must be clamped in the machine in accordance with the

set print variant (see the rollFLEX PX6 technical manual).
Displaying the fabric course of travel for the print variant

• Tap the [Fabric course of travel] button (7) for the print variant (6)
 The "Fabric course of travel for print variant" menu screen
(see Chapter 4.5.5) is displayed.

Fabric course of travel
for print variant
Setting the date and time

2. Tap the respective input field for “Date and time” (5)
 This opens the virtual keypad
(see Chapter 4.2.1, Fig. 4967/4002).
3. Enter the date (Day-Month-Year) / time (h-min-s)
 The entry is displayed in the respective input field.
5. Tap the [System time] button
 The entry is accepted as the system time.
System time

ON OPERATION
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
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. Tap the “Screen brightness” input field (2)
 This opens the virtual keypad
(see Chapter 4.2.1, Fig. 4967/4002).
3. Enter a brightness value (1 - 100)
 The input field (2) displays the screen brightness value.
The lower the brightness value is set, the longer the service life of
the screen.

ON OPERATION
Displaying / hiding shift settings

2. Tap the [Shift settings] button
 The controls for the shift settings (8), (9), (10), (11) and (12) are
displayed or hidden, according to your selection, where the controls
for setting the print variant (6) and (7) are located.
Green Displayed
Shift settings
Grey Hidden
Calibrating / cleaning the touchscreen

Information on calibrating the touchscreen is provided in Chapter 6.2,
and on cleaning the touchscreen in Chapter 6.1.
Calibrating the touchscreen
Open cleaning screen
Opening the “Machine settings” menu screen

• Tap the [Machine settings] button
 The "Machine settings" menu screen (see Chapter 4.5.4)
is displayed.
Machine settings
Opening the “Connection data and winder emergency operation” menu

screen
2. Tap the [Connection data and winder emergency operation] button
 The “Connection data and emergency operation” menu screen

ON OPERATION
Connection data and winder

emergency operation
Opening the “Factory settings” menu screen

2. Tap the [Factory settings] button
 The "Factory settings" menu screen (see Chapter 4.5.6)
is displayed.
Factory settings
Opening the “Report and recipe management” menu screen

• Tap the [Report and recipe management] button
 The “Report and recipe management” menu screen opens
(see Chapter 5.9).
Report and recipe

management
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:

ON OPERATION
Authorisation Password / Indicator in the status

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

1. Tap the password entry field (3) (see Chapter 4.5.1, Fig. 4967/4007)
 This opens the virtual keypad (see Chapter 4.2.1, Fig. 4967/4002)
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. 4967/4005 (5)). If the wrong password is entered,
authorisation level 0 is selected automatically.
Select authorisation level 2

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

ON OPERATION
Select authorisation level 4

2. Open the “Factory settings” menu screen (see Chapter 4.5.6)
3. Tap the password entry field (3) (see Chapter 4.5.6, Fig. 4967/4011)
 This opens the virtual keypad (see Chapter 4.2.1, Fig. 4967/4002)
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. 4967/4005 (5)).
The password for authorisation level 4 can be changed by a

Starlinger technician upon request.
4.5.3 Connection data and winder emergency operation
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 settings for emergency operation.

ON OPERATION
Fig. 4967/4010
[Emergency operation] button 4 Subnet mask

1
(bypass insertion arm) 5 Gateway
[Emergency operation] button 6 SMTP server
2
(bypass web break monitoring) 7 Sender e-mail address
3 IP address 8 Recipient e-mail address 1 / 2
Activating and deactivating emergency operation

• Tap the [Emergency operation] button
 The insertion arm or the web break monitoring system is bypassed,
or not, according to the selection.
Appearance Representation Status Name / Function

Bypassed /
Green emergency operation
activated
Emergency operation
Not bypassed /
Grey emergency operation
deactivated
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.

ON OPERATION
Modify the network settings
Switching the format cylinder on and off manually

2. Tap the [Format cylinder] button
 The format cylinder is extended or retracted depending
on the selection.
Green Extended
Format cylinder
Blue Retracted
Activating and deactivating cyclic operation of the hydraulic unit

• Tap the [Cyclic operation of the hydraulic unit] button
 Cyclic operation of the hydraulic unit for bleeding is activated or
deactivated according to the selection.
Green Active
Cyclic operation of the
hydraulic unit
Grey Not active
Bleeding the hydraulic system

1. Prepare for bleeding of the hydraulic lines (see the rollFLEX PX6
technical manual)
2. Tap the [Bleed hydraulic system] button
 The hydraulic line for extending and retracting the format cylinder is
bleed according to the selection.

ON OPERATION

Bleed hydraulic line for
Green retracting the format
cylinder Bleed the hydraulic
Bleed hydraulic line for system
Grey extending the format
cylinder
4.5.4 Machine settings
To open, tap the [Machine settings] button

This menu screen displays the machine settings.
Fig. 4967/4008
1 Ramp up / down (set) 3 Inch mode speed (set)

2 Factor "S ramp" (set) 4 Unwinder roll change speed (set)

ON OPERATION
4.5.5 Fabric course of travel for the print variant
To open, tap the [Fabric course of travel] button

with authorisation level 3 and additional information selected
This menu screen shows the course of travel of the fabric for the selected print
variant.
Fig. 4967/4009

ON OPERATION
4.5.6 Factory settings
The menu screens can be accessed by tapping the [Next] button

in the “Basic settings” submenu 2 - 3 times,
These menu pages show the factory settings which were configured by Starlinger
technicians. Some settings can also be configured by the customer, if
authorisation level 4 is selected.
Fig. 4967/4011
1 [Load factory settings] button

Password entry box (only for authorisation level 4 and Starlinger
2
technicians)
Loading the factory settings

2. Tap the [Load factory settings] button (1)
 The factory settings have been loaded.

5. WORKING WITH THE PROGRAM
5 WORKING WITH THE PROGRAM
5.1 Main menu
To open, tap the [Main menu] button
The machine's most important parameters can be checked and modified on this
menu screen.
Fig. 4967/5001
1 Machine status 9 EMERGENCY STOP status

2 Infeed status Production speed (set/actual) /
10
3 Unwinder 1 / 2 status Production speed indicator
4 Infeed status 11 Winder status
Infeed speed
5 12 Discharge status
(set calculated)
Discharge speed
6 Infeed speed (actual) 13
(set calculated)
7 Infeed drive utilisation (actual) 14 Discharge speed (actual)
Discharge drive utilisation
8 Safety cover status 15
(actual)
The set values can be changed with authorisation level 2 selected.
Machine / Infeed / Unwinder / Discharge / Winder status

Green bar In operation
Red circle Not operational

EMERGENCY STOP status

Yellow Not active
Flashes
Active
red/yellow
Buttons for submenus

Tapping a button in the working area of the main menu opens the corresponding
submenu. The submenus are described in detail in the chapters specified.
Button Name / Chapter Button Name / Chapter
Unwinder Drying system

5.2 5.6
Corona pre-treatment
Discharge
unit
5.7
5.3
Winder
5.8
Infeed
5.4
Information
5.10
Alarm management
Pressure 5.11
5.5 Basic settings
4.5
Increasing and reducing the production speed

The process of setting set values is described in Chapter 4.4.1. Alternatively, you
can proceed as follows:
2. Tap the [Production speed] button
 The “Production speed” set value (10) is increased or reduced by
one unit with each tap, depending upon which button is tapped.

Button Representation Process Name / Function
Arrow pointing up Increase

Production speed
Arrow pointing
Reduce
down
5.2 "Unwinder" submenu
To open, tap the [Unwinder] button

in the main menu
All of the relevant unwinder parameters can be checked and changed in this
menu.

Fig. 4967/5002
1 Roll diameter (actual) 9 Number of the unwinder

2 Core diameter (set) 10 Unwinder status
11 Starting diameter (set)
Min. roll diameter (set) for roll
3 12 Web tension (set)
change speed
13 Web edge control status
4 Brake status Gauge showing rocker arm
14
5 Braking force indicator position (info)
Web tension control parameters
6 15 Rocker arm position (info)
(info)
Water cooler status /
7 temperature (set/actual) / flow
volume (actual) Ramp status / Production speed
16 (set/actual) / Production speed
Cooling water distributor indicator
8 temperature (set) / flow volume
(actual)
Unwinder / Water cooler status


Web edge control status

Yellow
Fault
exclamation mark
Brake status
An angle measurement sensor measures the position of the rocker arm (15), and
uses this measurement to control the brake (4).

Green Applied
Grey Not applied
Ramp status

Green tick Production speed reached
Up arrow Increase production speed
Down arrow Reduce production speed
Switching the water cooler on and off

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


The process of setting the production speed is described in Chapter 5.1.
5.3 “Corona pre-treatment unit” submenu
To open, tap the

[Corona pre-treatment unit] button
in the main menu
All of the relevant parameters for the corona pre-treatment unit can be checked
and changed on this menu screen.
5.3.1 Status and control of the corona pre-treatment unit
Fig. 4967/5003
1 Corona status 3 Corona power gauge

2 Corona power (set/actual) 4 Power step (set)
Corona status


Starting and stopping the corona pre-treatment unit

When starting the corona pre-treatment unit, only the associated blower turns on
initially. Only when a production speed of 20 m/min is achieved does the device
start to work. When the device is stopped, its blower runs on for another 10 sec.
2. Tap the [Corona] button
 The corona is started or stopped according to the selection.
Appearance Representation Process Name / Function
Green Started
Corona
Blue Stopped
Increasing and reducing the corona power

2. Tap the [Corona power] button
 The “Corona power” set value (2) is increased or reduced by one
power step (4) with each tap, depending upon which button is
tapped.

Corona power
Arrow pointing
Reduce
down
5.3.2 Fault and status messages
To open, tap the [Next] button

on the Corona pre-treatment unit menu screen
in the main menu, with authorisation level 3 selected
This menu displays the fault and status messages of the corona pre-treatment
unit.

Fig. 4967/5004
1 Fault 3 Outputs
2 Status messages
Displaying status messages or outputs

2. Tap the [Status messages or outputs] button
 The status messages or outputs are displayed according
to the selection.
Appearance Representation Status / Process Name / Function
Display status
Green
messages
Grey Display outputs Status messages or outputs
Close the outputs

Blue
view

5.4 “Infeed” submenu
To open, tap the [Infeed] button

in the main menu
All of the relevant infeed parameters can be checked and changed in this menu.
Fig. 4967/5005
1 Infeed status
Speed 5 Production speed (set/actual)
2
(set calculated/actual)
3 Infeed drive utilisation (actual) 6 Production speed indicator
Motor temperature (actual)
4 Ramp status 7
and [Servo drives] button
Ramp status


Infeed status

Yellow
Fault
exclamation mark

Raising and lowering the pressure roller

• Tap the [Pressure roller] button
 This raises or lowers the pressure roller according to the selection.
Green Raised
Pressure roller
Blue Lowered
Opening the “Servo drives” menu screen

1. Display additional information
2. Tap the [Servo drives] button
 The “Servo drives” menu screen (see Chapter 5.5.3) is displayed.
Servo drives

5.5 “Print” submenu
To open, tap the [Print] button

in the main menu
All of the parameters for the machine's printing area can be checked and
changed in this menu.
5.5.1 Print overview
Fig. 4967/5006
Diameter of the format cylinder Load of raster drum printing unit

1 6
(set) drive (actual)
2 [Printing unit] button Load of format cylinder printing
7
3 Printing colour indicator unit drive (actual)
Ratio of print plate: roller
4 8 Printing unit status
circumference (actual)
Number of pieces printed per
5 9 Printing unit referencing status
minute (actual)
Infeed / Printing unit / Discharge status


Printing unit referencing status

Green tick Referenced
Exclamation
Not referenced
mark
Ramp status


Opening the “Printing unit” menu screen

• Tap the [Printing unit] button (2)
 The "Printing unit" menu screen (see Chapter 5.5.2) is displayed.
5.5.2 Printing unit
To open, tap the [Printing unit] button

in the "Print" submenu
All of the relevant printing unit parameters are checked and changed on this
menu screen.

Fig. 4967/5007
1 Printing unit number 6 Colour in the printing unit (set)

Viscosity control Drying system status / Drying
2 7
(set/actual/offset) system temperature (set/actual)
Raster drum temperature 8 Print start (set/actual)
3 (actual) and [Servo drives] Lengthways index position
button 9
(actual)
4 Display of the trunnion position 10 Repeat length (actual)
Display of the position of the Current position of the print
5 11
format cylinder wheel cylinder (actual)
Drying system status

Not
Red circle
operational
Yellow
Fault
exclamation mark
Selecting a printing unit

Use the [Next] and [Back] buttons (see Chapter 4.3.3) to scroll to the
corresponding menu screen.

Switching the measuring probe or valve on and off

2. Tap the [Measuring probe] or [Valve] button
 The measuring probe or valve is switched on or off depending on the
selection.
Green Switched on
Measuring probe or valve
Blue Switched off
Switching the drying system on and off

2. Tap the [Drying system] button
 The drying system is switched on or off depending on the selection.
Green Switched on
Drying system
Blue Switched off
Switching the raster drum on and off

2. Tap the [Raster drum] button
 The raster drum is switched on or off depending on the selection.
Representatio
Button Status Name / Function
n
Green Switched on
Raster drum
Blue Switched off

Resetting the direction change indicator

Depending upon the print variant selected, the trunnion of the raster drum must
be slid in or pulled out and the format cylinder wheel of the format cylinder turned,
according to the indicator.
A change in direction is indicated by the display of the trunnion position (4) and
display of the position of the format cylinder wheel (5) changing.
If the positions match the print variant, the direction change indicator is reset as
follows:
2. Tap the [Reset direction change] button
 The direction change indicator is reset.
Reset direction change
If the direction change has not been carried out properly for the
printing unit in question, the machine cannot be started!
Adjusting the lengthways index

For lengthways index adjustment, the format cylinder is turned by a motor. The
lengthways index adjustment (radial) is 360°. The format cylinder always remains
fixed in the up position during lengthways index adjustment.
2. Tap the [Lengthways index adjustment] button
 The format cylinder is rotated either clockwise or anticlockwise,
according to the selection.
 The actual value "Lengthways index position" (9) changes
accordingly and printing starts earlier or later, according to the
selection.

Rotate the format
Arrow pointing
cylinder anticlockwise,
left
printing starts later Lengthways index
Rotate the format adjustment
Arrow pointing
cylinder clockwise,
right
printing starts earlier

Resetting all drives to the 0 position

2. Tap the [Reset all drives to 0 position] button
 All drives are reset to the 0 position.
Reset drives to the 0 position
5.5.3 Servo drives
To open, tap the

[Servo drives] button
on the "Printing unit" menu screen in the "Print" submenu
with additional information
This menu screen displays information on the servo drives.
Fig. 4967/5008
1 Servo inverter name 5 Error counter / Error number

2 Main contactor status 6 Error text
3 Referencing status 7 Motor load
4 Servo converter status 8 Motor temperature

Main contactor, Referencing, Servo inverter status

Green bar ON or referenced
Red circle OFF or not referenced
Selecting the servo drive

The [Next] and [Back] buttons (see Chapter 4.3.3) can be used to scroll through
all the servo drives.
Resetting the fault

• Tap the [Reset fault] button
 The faults are reset.
Appearance Representation Status Meaning
Red Ready to reset

Resetting the fault
Green Fault is reset
If multiple faults have occurred on a drive, they must be reset

individually!
5.6 "Drying system" submenu
To open, tap the [Drying system] button

in the main menu
All of the relevant drying system parameters can be checked and changed in this
menu.

Fig. 4967/5009
1 Production speed (set) 4 Speed of the blower (set)

2 Production speed (actual) 5 Drying system status
Drying system temperature
6
3 Production speed indicator (set/actual)
7 Ramp status
Drying system status

Yellow
Fault
exclamation mark
Ramp status



Switching the drying system on and off

2. Tap the [Drying system] button
 The drying system is switched on or off depending on the selection.
Green Switched on
Drying system
Blue Switched off
5.7 "Discharge" submenu
To open, tap the [Discharge] button

in the main menu
All of the relevant parameters for the discharge can be checked and changed in
this menu.

Fig. 4967/5010
Discharge speed
1 Production speed (set/actual) 5
(set calculated/actual)
Discharge drive utilisation
2 Production speed indicator 6
(actual)
3 Motor temperature (actual) 7 Ramp status
4 Discharge status 8 [Production speed] button
Ramp status

Drive status

Yellow
Fault
exclamation mark


Raising and lowering the pressure roller

• Tap the [Pressure roller] button
 This raises or lowers the pressure roller according to the selection.
Green Raised
Pressure roller
Blue Lowered
Increasing and reducing the discharge speed

2. Tap the [Discharge speed] button
 The “Discharge speed” set value (5) is increased or reduced by one
unit with each tap, depending upon which button is tapped.

Discharge speed
Arrow pointing
Reduce
down
Opening the “Servo drives” menu screen

1. Display additional information
2. Tap the [Servo drives] button
 The “Servo drives” menu screen (see Chapter 5.5.3) is displayed.

Servo drives
5.8 "Winder" submenu
To open, tap the [Winder] button

in the main menu
All of the relevant winder parameters can be checked and changed in this menu.

5.8.1 Status and control of the machine area
Fig. 4967/5011
1 Contact pressure (set) 9 "Change roll" notice

2 Centre of the oscillator (set) 10 Delay before / after cutting (set)
Length of current roll of fabric
3 Oscillating movement status 11
(set)
Length for activating roll change
4 Oscillator centre position status 12
speed (set)
Winding tension in production /
5 Oscillator status 13
not in production (set)
Length of current roll of fabric
6 Oscillating path (set) 14
(actual)
Length of the last three rolls of
7 Number of layers (set) 15
fabric (actual)
8 Winder motor load (actual) 16 Winder drive status
Oscillator centre position status

Green tick In centre position
Red cross Not in centre position

Oscillating movement status

Green bar / red
Move left
circle
Red circle /
Move right
green bar
Two red circles No movement
Oscillator status
Ensures the regular composition of the fabric roll. The winder is regulated by
motor, within the set traversing range.
Green Active
Red Not active
Winder drive status

Green bar Switched on
Red circle Switched off
Red exclamation
Fault
mark
Centring the oscillator

2. Tap the [Centre oscillator] button
 The oscillator is centred.
 The status of the oscillator changes accordingly.
Centre the oscillator

Switching the traverse on and off

2. Tap the [Oscillator] button
 The status of the oscillator changes accordingly.
 The oscillator is switched on or off depending on the selection.
Oscillator
Resetting the production counter

2. Tap the [Reset production counter] button
 The length of the current roll of fabric (14) is reset.
Reset the production counter
Opening the “Shift statistics” menu screen

• Tap the [Shift statistics] button
 The "Shift statistics" menu screen (see Chapter 5.8.3) is displayed.
Shift statistics
Opening the “Winder diagnostics” menu screen

• Tap the [Winder diagnostics] button
 The "Winder diagnostics" menu screen (see Chapter 5.8.2) is
displayed.

“Winder diagnostics”
Green
menu screen is open
Winder diagnostics
“Winder diagnostics”
Grey menu screen is not
open
5.8.2 Winder diagnostics
To open, tap the [Winder diagnostics] button

in the "Winder" submenu
On this menu screen, you can reference and manually move the winder.

Fig. 4967/5012
1 Reference positions status 14 Hydraulic unit status

2 Internal program steps
15 Swivel arm pin status (DS)
3 Auxiliary feed status
4 Auxiliary feed status (Channel 2) [Swivel arm pins]
16
5 Swivel arm tilted status button
Swivel arm vertical status / Winder shaft in winding arms
6 17
button [tilt/engage] status
Absolute position of the 18 Insertion arm pin status (OS)
7 potentiometric rotary encoder
(actual) 19 Insertion arm reference status
Blade in limit position status
8 20 Insertion arm pin status (DS)
(DS)
Winder shaft in swivel arm Winder shaft in insertion position
9 21
status status (DS)
22 Safety light barrier status
10 Swivel arm pin status (OS)
23 Winding arm reference status
11 Swivel arm reference status 24 Oscillator limit position status
Winder shaft in insertion position
12 Cut-off device reference status 25
status (OS)
[Adjust oscillator]
13 Swivel arm fully extended status 26
button

Reference positions status

Green tick Referenced
Red cross Not referenced
Oscillator status

Green tick Centred
Red cross Not centred
Sensor status

Green bar Occupied
Red bar Not assigned
Starting referencing
2. Tap the [Start referencing] button
 Referencing is started.
Starting referencing
Cancelling referencing
2. Tap the [Cancel referencing] button
 Referencing is reset.
Cancel referencing

Switching operating modes

2. Tap the [Operating mode] button
 The winder operates in the selected operating mode.
Appearance Representation Operating mode Name / Function
Green Automatic
Operating mode
Blue Manual
Raising / lowering the swivel arm

2. Activate manual mode
 The [Raise / lower swivel arm] button is displayed.
3. Tap the [Raise / lower swivel arm] button
 The swivel arm is raised or lowered, according to the selection.
Appearance Representation Process Name

Arrow pointing
Raise swivel arm
up Raise / lower
Arrow pointing the swivel arm
Lower swivel arm
down
Tilting / engaging the swivel arm

 The [Tilt / engage swivel arm] button (6) is displayed.
3. Touch the [Tilt / engage swivel arm] button (6)
 The swivel arm is tilted or engaged, according to the selection.
Appearance Representation Process Meaning

Arrow pointing
Tilt swivel arm
left Tilt / engage
Arrow pointing the swivel arm
Engage swivel arm
right

Opening and closing the pins of the swivel arm

 The [Swivel arm pins] button (16) is displayed
3. Tap the [Swivel arm pins] button (16)
 This opens or closes the pins of the swivel arm, according to the
selection.
Appearance Representation Process Name

Arrow pointing
Open
left
Swivel arm pins
Arrow pointing
Close
right
Adjusting the oscillator

 The [Adjust oscillator] button (26) is displayed
3. Tap the [Adjust oscillator] button (26)
 The oscillator is moved left or right, according to the selection.
Appearance Representation Process Meaning

Arrow pointing
Move oscillator left
left
Adjusting the oscillator
Arrow pointing
Move oscillator right
right
Centring the oscillator

2. Tap the [Centre oscillator] button
 The oscillator is centred.
Centre the oscillator

5.8.3 Shift statistics
To open, tap the [Shift statistics] button

This menu displays the shift statistics – provided that shift data has been
registered (see Chapter 4.5.1).
Fig. 4967/5013
Production length for the

1 Date 2
respective shift (actual)
5.8.4 Advanced winding mode
To open, tap the [Advanced winding mode] button

In this menu you can set the winder's working parameters, based on the roll
diameter.

Fig. 4967/5029
Graphical representation of values

(1), (2), (3):
1 Winding tension (set)
• X-axis: roll diameter
• Y-axis: set values
6 • Orange line: winding tension
• Blue line: contact pressure
2 Contact pressure (set) • Green line: roll diameter
• Turquoise line: simulated roller
diameter
3 Roll diameter (set) 7 Roll diameter for simulation
4 Contact pressure (actual) 8 Contact pressure based on (7)
5 Winding tension (actual) 9 Winding tension based on (7)
Setting the contact pressure and winding tension

2. Tap the [Set contact pressure] or [Set winding tension] button
 The contact pressure or winding tension is carried over from the first
line of the table to all lines.
Set contact pressure
Set winding tension

Setting the standard contact pressure and winding tension

2. Tap the [Standard contact pressure and winding tension] button
 Standard values are set for the contact pressure and the winding
tension.
Set standard contact pressure

and winding tension
5.9 “Report and recipe management" submenu

This menu is used to create reports and recipes (optional) and save them as a
file.
5.9.1 Overview
To open, tap the

[Report and recipe management] button
in the “Basic settings” submenu
This menu screen shows an overview of report and recipe management.
Fig. 4967/5014

Button Name / Function Button Name

Production report
Production report
folder
Setup report Setup report folder
Safety system report Screenshots folder
Move one item

USB stick folder
upwards
Move one item

Safety control folder
downwards
YES NO
Opening a file
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.
4. Tap the [Open file] button
 The "Display data" menu screen opens (see Chapter 5.9.2), and the
contents of the file is displayed.
Open a file
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. 4967/4010 (8)).
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 USB port on the switching cabinet of the
operating unit (see the rollFLEX PX6 technical manual)
3. Open the folder by tapping the [USB stick folder] button
5. Tap the [Import file] button
 The file is saved to the control unit's memory card.
 If a recipe has been imported:
The “Recipes” folder contains the imported file.
 If a text file has been 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:
2. Connect the USB stick to the USB port on the switching cabinet of the
operating unit (see the rollFLEX PX6 technical manual)

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
 A prompt asks if you really want to delete the file.
5. Confirm the prompt by tapping the [YES] button (tapping the [NO]
button cancels the delete process at this point)
 The file is irreversibly deleted!
Delete a file
5.9.2 Displaying data
To open, tap the [Open file] button

in the “Report and recipe management” submenu,
This menu screen shows the contents of a file.

Fig. 4967/5015
1 Contents of the file 2 e-mail send status
Sending the contents of a file by e-mail

• Tap the [Send contents of file by e-mail] button
 The displayed contents of the file are sent by e-mail to the recipients
listed in the fields “e-mail address recipient 1 / 2” (see Chapter 4.5.3,
Fig. 4967/4010 (8)).
Send the contents of a file by

e-mail
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 in more detail.
This menu screen is used to generate the production report and save it to a file.

Fig. 4967/5016
1 Report name 4 Type

2 User name 5 Comment
3 Material 6 Report preview
Updating the report preview

• Tap the [Update report] button
 The report preview (6) is updated.
Update the report
Saving the report

1. Enter the report name (1), user name (2) and comment (5)
2. 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 machine 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. 4967/5017
1 User name
3 Report preview
2 Comment

Update the report
Saving the report

1. Enter the user name (1) and comment (2)

Save the report
5.9.5 Safety system report
To open, tap the [Safety system report] button

This menu screen is used to generate the safety system report and save it to a
file.
Fig. 4967/5018
1 User name
3 Report preview
2 Comment

Update the report

Saving the report

1. Enter the user name (1) and comment (2)
Save the report
5.10 “Information” submenu

This menu displays information on the different machine areas.
5.10.1 Control unit
To open, tap the [Information] button

in the main menu
This menu screen is used to display control unit data, battery status and machine
operating hours.
Fig. 4967/5019
1 CPU information 4 IP address

2 Operating hours 5 Ping result
3 Battery status 6 Ping IP address

Battery status
The indicator (3) provides information about the status of the battery. If it is red,
the battery must be changed (see Chapter 6.3).

Green Battery is OK
Red Change battery
Checking the network connection

2. Set the ping IP address (6)
3. Tap the [Ping] button
 The result of the test is displayed as the “Ping result” (5).
Ping
Opening the logbook for the control unit

• Tap the [Control unit logbook] button
 The “Control unit logbook” menu screen (see Chapter 5.10.2)
is displayed.
Control unit logbook
Displaying hardware and software data

• Tap the [Hardware and software data] button
 The “Hardware and software data” menu screen opens
Hardware and software data

5.10.2 Control unit logbook
To open, tap the [Control unit logbook] button on the "Control unit"
menu screen in the "Information"
submenu
This menu screen displays the logbook for the control unit, allowing you to
analyse faults with the bus system and control unit crashes.
Fig. 4967/5020
Exporting data
1. Connect the USB stick to the "USB1" port of the control panel
(see the manufacturer's documentation)
2. Tap the [Export data] button
 The data is saved to the USB stick.
Data is being
Green
exported
Exporting data
Available for
Blue
selection

5.10.3 Hardware and software data
To open, tap the [Hardware and software] button

on the "Control unit" menu screen
in the "Information" submenu
This menu screen allows you to check the hardware and software data for the
control unit.
Fig. 4967/5021
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.
Arrow pointing up Scroll up

Scroll
Arrow pointing
Scroll down
down

5.10.4 Communications interfaces
To open, tap the [Back] button

on the "Control unit" menu screen
This menu provides a representation of the bus system.
Fig. 4967/5022
1 [Safety control info] button

3 [Alarm history] button
2 [Control unit] button
Opening the “Safety control info” menu screen

2. Tap the [Safety control info] button
 The “Safety control” menu screen
Opening the “Control unit” menu screen

2. Tap the [Control unit] button
 The “Control unit” menu screen

5.10.5 Safety control
To open, tap the [Safety control] button

on the "Communications interfaces" menu screen
This menu screen displays information about the safety control.
Fig. 4967/5023
1 Safety control status 5 System version

Project CRC (cyclic redundancy
2 Boot state 6
check) checksum
3 Safe OS state 7 Author
4 Program version 8 Date / time of the last change
Safety control status

Green bar Normal operation
Not in normal
Red circle
operation
Updating the data

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

Update the data
Cancelling read data

• Tap the [Cancel read data] button
 The process of reading the data is cancelled.
Cancel read data
Opening the "Safety control logbook" submenu

• Tap the [Safety control logbook] button
 This opens the "Safety control logbook" menu screen
Safety control logbook
Opening the "SafeLogic commissioning" submenu

This submenu is only accessible to Starlinger technicians.
SafeLogic commissioning
5.10.6 Safety control logbook
To open, tap the [Safety control logbook] button

on the "Safety control info" menu screen
The safety control logbook is displayed on this menu screen.

Fig. 4967/5024
Exporting the logbook

1. Connect a USB stick to the "USB1" port on the control panel (see the
manufacturer's documentation) (it must contain a folder called "LOG")
3. Tap the [Export logbook] button
 The logbook is saved to the “LOG” folder on the USB stick.
Export the logbook
5.10.7 Alarm history of the frequency converter
To open, tap the

[Alarm history of the frequency converter] button
on the “Control unit” menu screen
in the “Information” submenu,
with authorisation level 3 selected and additional information
displayed
This menu screen shows the alarm history of the selected frequency converter.

Fig. 4967/5025
1 Sequential numbers 3 Selected frequency converter

2 Alarm text 4 Alarm status
Alarm status

Green circle Alarm reset or rectified
Yellow circle Active alarm
5.11 “Alarm management” submenu
To open, tap the [Alarm management] button

in the main menu
In this menu, you can check user actions and alarms and reset alarms, and
export them to a USB stick if required.

5.11.1 Active alarms
Fig. 4967/5026
1 Alarm text 3 Status

2 Alarm number 4 Time that alarm occurred
Alarm status

Arrow pointing up Incoming alarm
Arrow pointing down Outgoing alarm
Green circle Alarm reset
Alarm procedure
All problems which occur during operation are immediately displayed in the status
area (see Chapter 4.3.1, Fig. 4967/4005 (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
5.11.3).
Shutting off the horn

• Tap the [Shut off horn] button
 The horn is shut off.

Shut off the horn
Resetting the alarm

• Tap the [Reset alarm] button
 The alarm is reset.
 The status symbol switches from yellow to green.
Reset the alarm
Displaying user actions or the alarm history

• Tap the [User actions] or [Alarm history] button
 The "User actions" menu screen (see Chapter 5.11.2) or "Alarm
history" menu screen (see Chapter 5.11.3) is displayed.
User actions
Alarm history
5.11.2 User actions
To open, tap the [User actions] button

in the "Alarm management" submenu
All of the user actions (starting the machine, 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. 4967/5027
1 Description of the action 3 Action status

Date and time action was
2 Action number 4
performed
Displaying active alarms or the alarm history

• Tap the [Active alarms] or [Alarm history] button
 The "Active alarms" menu screen (see Chapter 5.11.1) or "Alarm
history" menu screen (see Chapter 5.11.3) is displayed.
Active alarms
Alarm history
5.11.3 Alarm history
To open, tap the [Alarm history] button

in the “Alarm management” submenu
This menu screen displays alarms that occurred in the past, and allows you to
export them onto a USB stick.

Fig. 4967/5028
1 Alarm number 4 Date of the alarm

2 Alarm text 5 Time of the alarm
3 Alarm type 6 Alarm status
Alarm status

Arrow pointing up Incoming alarm
Arrow pointing down Outgoing alarm
Green circle Alarm reset
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.
Alarm type

Exporting alarms
1. Connect the USB stick to the USB1 port (see the manufacturer's
documentation)
3. Tap the [Export alarms] button
 The alarms are saved to the USB stick.
Alarms are being

Green
exported
Export alarms
Available for
Blue
selection
Displaying the active alarms or user actions

• Tap the [Active alarms] or [User actions] button
 The "Active alarms" menu screen (see Chapter 5.11.1) or "User
actions" menu screen (see Chapter 5.11.2) is displayed.
Active alarms
User actions

5.12 Menu structure

Screenshots of all menu screens with chapter numbers and nesting:
5.1;00
Main menu
5.1
4.5.1;200 4.5.3;201
Basic settings
4.5
4.5.4;230 4.5.6;210 4.5.6;211
4.5.5;0
6.1;0
Cleaning the
touchscreen
6.1
6.2;0
Calibrating the
touchscreen
6.2
5.2;10
Unwinder
5.2
5.3.1;60 5.3.2;65
Corona pre-
treatment unit
5.3
5.4;20
Infeed
5.4

5.1;00
Main menu
5.1
5.5.1;30 5.5.2;70 5.5.3;113

Pressure
5.5
5.6;50
Drying system
5.6
5.7;40
Discharge
5.7
5.8.1;80
Winder
5.8
5.8.2;85
5.8.3;90
5.8.4;81
5.11.1;140 5.11.2;150
Alarm
management
5.11
5.11.3;145

5.1;00
Main menu
5.1
Report and 5.9.1;130 5.9.2;139

recipe
management
5.9
5.9.3;131
5.9.4;135
5.9.5;137
5.10.1;112 5.10.2;115
Information
5.10
5.10.3;240
5.10.4;111 5.10.5;120 5.10.6;116
5.10.7;119

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
Cleaning screen

in the main menu
and by tapping the [Open cleaning screen] button

in the “Basic settings” submenu
The cleaning screen opens:

6. MAINTENANCE
Fig. 4967/6001
• Cleaning the touchscreen

 While the cleaning screen is selected, it is not possible to perform
any user actions on screen.
 During the last 5 sec of cleaning time, the following notice is
displayed:
Fig. 4967/6002
 Once the cleaning time has elapsed, the main menu opens
automatically.
For more information on cleaning the touchscreen, see the

manufacturer's documentation.
Closing the cleaning screen before the cleaning time has elapsed
• Touch the [Close cleaning screen] button for 5 sec
 The main menu opens.

6. MAINTENANCE
Close cleaning screen
6.2 Calibrating the touchscreen

The touchscreen must be calibrated under the following conditions:
• After a software update (see Chapter 6.5)
• If the location of the controls on the display does not match up with the
area that has to be tapped to activate them
Calibration screen

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

in the "Basic settings" submenu for 5 sec
If the touchscreen is very badly misaligned, the calibration screen

can also be opened by pressing and holding the <Reset fault>
push button for 30 sec.
Fig. 4967/6003
• Tap the crosshairs which appear in the corners, one after another
 The touchscreen is calibrated.

6. MAINTENANCE
6.3 Changing the battery

The battery must be changed if it is flat (see Chapter 6.4, Fig. 4967/6004 (4)).
This resets the set values to the factory settings. An alarm appears on screen.
For further information on changing the battery, see the

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.
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 according to the instructions of
a Starlinger technician!
Fig. 4967/6004
1 Ejector 3 Safety catch

2 Memory card 4 Battery

6. MAINTENANCE
Removing and replacing the memory card

1. Note down the IP address (see Chapter 4.5.3)
2. Switch off the machine
3. Open the cover on the control panel
 The memory card can be seen on the side of the control panel.
4. Pivot the safety catch (3) away
5. Push the ejector (1) (e.g. using a pen)
 The memory card (2) now protrudes slightly from the case.
6. Remove the memory card (2), taking note of its current orientation
7. If necessary, perform a software update (see Chapter 6.5)
8. Carefully push the new or updated memory card into the slot with the
correct orientation
9. Pivot the safety catch (3) over the card
10. Switch on the machine
11. Set the IP address (see Chapter 4.5.3)
6.5 Software update
NOTE!
Risk of data loss!
Perform a backup of your data before carrying out a software
update!
For further information on the software update, see the


7. TROUBLESHOOTING
7 TROUBLESHOOTING
When contacting our Customer Service Center, please have the following
information to hand:
• Serial number of the machine
• General description of the problem
• Precise wording of the alarm text AND the alarm number, as displayed
in the Alarm management screen (see Chapter 5.11)
• 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 machine 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 5.11).
Structure of the alarm description

All of the alarms are described below in a table as in this example:
Alarm number Alarm text

Cause Remedy
Description of the possible cause(s) Procedure to rectify
Some alarm texts contain expressions in curly brackets. When the

alarm is displayed, these are replaced by additional information.

7. TROUBLESHOOTING
7.1 Alarm group 00 - System alarms
00-000 All alarms reset

Cause Meaning
Status indicator Active alarms were reset automatically.
00-001 All alarms bypassed

Cause Meaning
Status indicator All alarms were bypassed.
00-002 System initialised

Cause Meaning
The system is reinitialised The system is restarted
00-003 Printout of alarms restarted

00-004 Printer not ready
00-005 Alarm data cannot be read
00-006 Printer buffer overrun
Cause Meaning
See the manufacturer's documentation for
System alarm
the control panel
00-007 Battery flat

Cause Remedy
Operating unit battery is flat Change battery (see Chapter 6.3)
7.2 Alarm group 02 - Servo controller
02-001 Format cylinder 1 fault

Cause Remedy
Format cylinder 1 drive fault Reset drive
02-002 Warning: Format cylinder 1 lag error

Cause Remedy
Lag error See Chapter 7.16.7

7. TROUBLESHOOTING
02-003 Warning: Format cylinder 1 thermal load

Cause Remedy
Format cylinder 1 overheating Reduce production speed
02-004 Warning: Format cylinder 1 motor temperature

Cause Remedy
DC drive has overheated See Chapter 7.14.1
02-005 Format cylinder 1 not referenced

Cause Remedy
• Reset the EMERGENCY STOP (see
Format cylinder 1 not referenced the rollFLEX PX6 technical manual)
• or re-reference Format cylinder 1
02-006 Format cylinder 1 motor excess temperature

Cause Remedy
02-007 Printing unit 1 incorrect direction of rotation

Cause Remedy
Incorrect direction of rotation for Printing
Check print variant (see Chapter 4.5.5)
unit 1
Check direction change for Printing unit 1
Direction change not performed correctly
(see Chapter 5.5.2)
02-011 Raster drum 1 fault

Cause Remedy
Raster drum 1 drive fault Reset drive
02-012 Warning: Raster drum 1 lag error

Cause Remedy

7. TROUBLESHOOTING
02-013 Warning: Raster drum 1 thermal load

Cause Remedy
Raster drum 1 overheating Reduce production speed
02-014 Warning: Raster drum 1 motor temperature

02-016 Raster drum 1 motor excess temperature
Cause Remedy
02-017 Inking unit drive 1 motor protection

Cause Remedy
Motor protection has tripped See Chapter 7.14.2

Cause Remedy

Cause Remedy

Cause Remedy

Cause Remedy

Cause Remedy

7. TROUBLESHOOTING

Cause Remedy

Cause Remedy
unit 2
(see Chapter 5.5.2)

Cause Remedy

Cause Remedy

Cause Remedy

Cause Remedy

Cause Remedy

Cause Remedy

7. TROUBLESHOOTING

Cause Remedy

Cause Remedy

Cause Remedy

Cause Remedy

Cause Remedy

Cause Remedy
unit 3
(see Chapter 5.5.2)

Cause Remedy

7. TROUBLESHOOTING

Cause Remedy

Cause Remedy

Cause Remedy

Cause Remedy

Cause Remedy

Cause Remedy

Cause Remedy

Cause Remedy

7. TROUBLESHOOTING

Cause Remedy

Cause Remedy

Cause Remedy
unit 4
(see Chapter 5.5.2)

Cause Remedy

Cause Remedy

Cause Remedy

Cause Remedy

7. TROUBLESHOOTING

Cause Remedy

Cause Remedy

Cause Remedy

Cause Remedy

Cause Remedy

Cause Remedy

Cause Remedy

Cause Remedy
unit 5
(see Chapter 5.5.2)

7. TROUBLESHOOTING

Cause Remedy

Cause Remedy

Cause Remedy

Cause Remedy

Cause Remedy

Cause Remedy

Cause Remedy

Cause Remedy

7. TROUBLESHOOTING

Cause Remedy

Cause Remedy

Cause Remedy

Cause Remedy
unit 6
(see Chapter 5.5.2)

Cause Remedy

Cause Remedy

Cause Remedy

7. TROUBLESHOOTING

Cause Remedy

Cause Remedy
7.3 Alarm group 03 - Drives
03-013 Oscillator rotary encoder fault

03-014 Infeed rotary encoder fault
03-015 Turning station rotary encoder fault
03-016 Discharge rotary encoder fault
03-017 Winder rotary encoder fault
03-018 Drying system rotary encoder fault
Cause Remedy
Rotary encoder fault See Chapter 7.16.6
03-019 Oscillator inverter overtemperature

03-020 Infeed inverter overtemperature
03-021 Turning station inverter overtemperature
03-022 Discharge inverter overtemperature
03-023 Winder inverter overtemperature
03-024 Drying system inverter overtemperature
Cause Remedy
Frequency converter fault See Chapter 7.14.3

7. TROUBLESHOOTING
03-025 Oscillator motor overtemperature

03-026 Infeed motor overtemperature
03-027 Turning station motor overtemperature
03-028 Discharge motor overtemperature
03-029 Winder motor overtemperature
03-030 Drying system motor overtemperature
Cause Remedy
7.4 Alarm group 04 - Unwinder
04-000 Fault on the sensors of the web edge control

Cause Remedy
Sensor fault See Chapter 7.12
04-001 Both limit switches of the web edge control occupied

Cause Remedy
Limit switches blocked by foreign bodies Clean limit switches
Limit switches incorrectly connected Check connection
04-002 Web edge control drive fault

Cause Remedy
04-003 Fabric covering all web edge sensors

04-004 Fabric outside of the area of the web edge sensors
Cause Remedy
Web edge control fault See Chapter 7.18.2
04-005 Unwinder at operating side limit switch

04-006 Unwinder at drive side limit switch
Cause Remedy
Limit position fault See Chapter 7.18.4

7. TROUBLESHOOTING
04-007 Brake 1 not in position - roll cannot be changed

04-008 Brake 2 not in position - roll cannot be changed
Cause Remedy
• Install brake unit
The brake unit has been removed from
• Check position of roll toggle switch
the winder shaft
• Check wiring
04-009 Winder shaft 1 not locked - roll cannot be changed

04-010 Winder shaft 2 not locked - roll cannot be changed
Cause Remedy
• Check that the winder shaft is inserted
The locking pin for the winder shaft could properly
not be extended • Check the reed switch
• Check pneumatic system
04-012 Brake <> Locking pin 1 fault

04-013 Brake <> Locking pin 2 fault
Cause Remedy
• Check position of roll toggle switch
• Check that the winder shaft is inserted
The position of the locking pin of the properly
winder shaft does not match the position
• Check the reed switch
of the brake unit.
• Check pneumatic system
• Check wiring
04-014 Both web carriages uncoupled

Cause Remedy
Both of the unwinder brake units have Move the brake into position, so that the
been uncoupled. machine can be put into operation.

7. TROUBLESHOOTING
04-015 Roll 1 ultrasound sensor defective

04-019 Web accumulator not referenced
Cause Remedy
Sensor fault See Chapter 7.12
04-020 Fabric covering the full web edge sensor

04-021 Fabric located outside of the web edge sensor
Cause Remedy
Web edge control fault See Chapter 7.18.2
04-022 Web edge drive not ready

Cause Remedy
04-023 Web edge drive motor temperature too high

Cause Remedy
04-024 Web edge drive overloaded

Cause Remedy

7. TROUBLESHOOTING
04-025 Unwinder stepper motor referencing timeout

Cause Remedy
• Check the control, connection and
wiring of the stepper motor and the
stepper motor module, following the
circuit diagram
Referencing fault • Compare models with those specified
(the limit position of the spindle at the stop on the circuit diagram
on the operating side was not reached) • Check the mechanism, spindle,
coupling, etc.
• Attempt to move the stepper motor
manually
• Carry out referencing again
04-026 Communications error, stepper motor module

Cause Remedy
• Check the supply for the bus node, on
which the stepper motor module is
located
• Check the wiring and connections of
the motor and module according to
Stepper motor module fault
the circuit diagram
• Compare models fitted with those
specified on the circuit diagram;
replace the stepper motor module if
necessary
04-027 Unwinder stepper motor referencing necessary

Cause Remedy
Perform sensor position referencing for
Sensor position referencing for the
the specified unwinder (see the rollFLEX
specified unwinder not set
PX6 technical manual)
04-030 Unwinder motor protection, web edge control

Cause Remedy
04-031 Web edge actuator drive voltage error

Cause Remedy
Stepper motor module error See Chapter 7.15.2

7. TROUBLESHOOTING
04-032 Web edge actuator drive excess temperature

Cause Remedy
• Check mechanism for ease of
The stepper motor module of the web movement
edge actuator drive is overheated.
• Allow module to cool down
04-033 Web edge actuator drive overcurrent

Cause Remedy
• Check the wiring for short-circuits
The double motor current was measured
in the motor windings. • Measure the resistance of the motor
windings
04-034 Roll 1 safety plate not in position

04-035 Roll 2 safety plate not in position
Cause Remedy
The safety plate of the fabric unwinder is Fold the safety plate upwards until it
not in the upper limit position. securely engages.
Fabric web accumulator not in change position - check starting

04-037
diameter
Cause Remedy
The web accumulator was not in the
Adjust starting diameter upwards (see
intended position at the time of the roll
Chapter 5.2)
change.
04-038 Fabric preparation failed

Cause Remedy
The new roll of fabric did not move during • Pay attention to the feed diagram (see
the roll change due to the fabric the rollFLEX PX6 technical manual)
preparation. • Prepare the fabric accordingly
04-039 Web accumulator drive fault

Cause Remedy

7. TROUBLESHOOTING
04-040 Fabric roll 1 minimum diameter

Cause Remedy
Prepare a new roll of fabric and perform a
The fabric roll has fallen below the set
roll change when the current roll reaches
minimum diameter during production.
its end.
04-053 Fabric preparation not acknowledged

Cause Remedy
The prepared roll of fabric was not After the roll preparation is complete,
activated with the push button (see the press the push button to enable an
rollFLEX PX6 technical manual). automatic change.
04-055 Roll 1 safety plate not in position at time of change

04-056 Roll 2 safety plate not in position at time of change
Cause Remedy
The safety plate is not in the upper limit
Move safety plate to upper limit position
position at the time of the roll change.
Roll 1 diameter for automatic roll change too large ({RollDia1} >
04-057
{ChgDia})
Roll 2 diameter for automatic roll change too large ({RollDia2} >
04-058
{ChgDia})
Cause Remedy
• Check the adjustment of the winder
shaft used
A web break occurred before the min. • Select winder shaft size for the roll
diameter for the roll change was reached. being changed to
• Use a roll of fabric without winding
defects
04-090 Unwinder 1, fault on speed measurement sensor

04-091 Unwinder 2, fault on speed measurement sensor
Cause Remedy
Sensor or wiring faulty Check speed sensor

7. TROUBLESHOOTING
04-099 <Stop> push button or jumper 24 V to +E02-A1.3 DI-8 absent

Cause Remedy
When the machine was started up, no
Connect a jumper to the mentioned digital
voltage was measured on the
input or retrofit a Stop push button
corresponding digital input.
<Stop> push button of the fabric unwinder Do not push the <Stop> push button
was held down during machine startup. during machine startup
7.5 Alarm group 08 - Winder
08-001 No valid parameters in the winder drive

08-002 No valid parameters in the insertion arm drive
Cause Remedy
Frequency converter must be
The parameters in the oscillator drive do
reprogrammed (contact Starlinger
not match what is stored.
Customer Service Center)
08-020 Winder drive fault

Cause Remedy
08-021 Winder drive temperature too high

Cause Remedy
08-022 Winder drive rotary encoder fault

Cause Remedy
Rotary encoder fault See Chapter 7.16.6
08-023 Winder motor temperature too high

Cause Remedy
08-025 Insertion arm drive fault

Cause Remedy

7. TROUBLESHOOTING
08-026 Insertion arm motor temperature too high

Cause Remedy
08-030 Motor protection switch, hydraulic unit or oscillator

08-031 Motor protection switch, winder drive blower
Cause Remedy
08-041 Hydraulic system oil filter dirty

Cause Remedy
• Replace filter
Filter dirty
• Check connection cable
08-042 Hydraulic system oil level low

Cause Remedy
Oil level too low Top up oil
08-043 Hydraulic system oil temperature too high

08-044 Hydraulic system oil cooler fault
Cause Remedy
• Check hydraulic system
Oil temperature > 70°C
• Check fan
08-050 Winder not referenced

Cause Remedy
Perform referencing
Winder not referenced
(see Chapter 5.8.2)
Sensor fault See Chapter 7.12.1
08-052 Winding arm diameter sensor, fault

Cause Remedy

7. TROUBLESHOOTING
08-053 Maximum winding diameter

Cause Remedy
Max. winding diameter reached Initiate roll change
08-054 No winder shaft in the swivel arm

Cause Remedy
08-055 Insertion arm outside

Cause Remedy
• Remove winder shaft from the
insertion arm
Insertion arm has not been moved into • Move insertion arm to standby
standby position (is swung out) and position
winding diameter is too great due to
machine stop. • Set down roll with winding arm.
• Stop winder and perform referencing,
if necessary (see Chapter 5.8.2)
08-056 Swivel arm not transferred

Cause Remedy
• Winder diameter reached, roll has not
reached winding arm, machine stop
Manual transfer to winding arm
• Winding arm moved to home position
too late
08-057 No winder shaft in the winding arm

Cause Remedy
08-058 Transfer swivel arm – winder shaft jammed

Cause Remedy
Winder shaft not released from swivel arm
Reset swivel arm manually or perform
or swivel arm not swinging back into
referencing (see Chapter 5.8.2)
vertical position within 5 s
08-059 Swivel arm is not in transfer position

Cause Remedy

7. TROUBLESHOOTING
08-060 Winding arm sensor outside of the range

Cause Remedy
Readjust rotary encoder, see Circuit
Winding arm sensor not in specified range diagram or rollFLEX PX6 technical
manual
08-061 Blade not on the operating side

Cause Remedy
08-062 Insertion arm disabled

Cause Remedy
• Insertion arm is disabled
(see Chapter 4.5.3) Check the insertion arm, and if necessary
enable it (see Chapter 4.5.3)
• Machine in emergency operation
08-070 Reference point for winding arm absent

Cause Remedy
Perform referencing
Winding arm not referenced
(see Chapter 5.8.2)
08-071 Reference point for insertion arm absent

Cause Remedy
Perform referencing
Insertion arm not referenced
(see Chapter 5.8.2)
08-072 Reference point for swivel arm absent

Cause Remedy
Perform referencing
Swivel arm not referenced
(see Chapter 5.8.2)
08-073 Reference point for cutting unit absent

Cause Remedy
Perform referencing
Cutting unit not referenced
(see Chapter 5.8.2)

7. TROUBLESHOOTING
7.6 Alarm group 12 - Corona
12-000 Corona fault

Cause Remedy
If corona shows a notification, read fault
Corona is reporting a fault
from the notification
12-001 Corona: EMERGENCY STOP

Cause Remedy
Reset the EMERGENCY STOP (see the
EMERGENCY STOP active
rollFLEX PX6 technical manual)
12-002 Corona: frequency converter excess temperature

Cause Remedy
12-003 Corona: suction air speed too low

Cause Remedy
Ozone extraction unit is switched off Switch on ozone extraction unit
• Check extraction tubes and clean if
Extraction tubes are blocked necessary
• Empty receptacle
• Clean the flow sensor
Flow sensor is soiled or defective • Check wiring, if necessary replace the
flow sensor
12-004 Corona: frequency converter overcurrent

Cause Remedy
Corona: intermediate circuit voltage of the frequency converter too

12-005
low
Cause Remedy
• Check power supply and cable
The power supply has partially or connections
completely failed. • Check wiring and adjustment of the
motor protection switch

7. TROUBLESHOOTING
12-006 Corona: electrode defective

Cause Remedy
One or more electrodes are broken and
Replace defective electrode
damaged.
Insulation of lines carrying high voltage
Check lines and replace if necessary
faulty.
12-007 Corona: IGBT frequency converter defective

Cause Remedy
12-008 Corona: mains voltage missing

12-009 Corona: mains contactor defective
Cause Remedy
• Check cables and contacts
A mains phase is missing. • Ensure that mains contactor is
working properly
12-010 Corona: high voltage release not set

Cause Remedy
• Check wiring between safety control
The high voltage release for the corona and corona frequency converter.
station was not provided. • Reset the EMERGENCY STOP (see
the rollFLEX PX6 technical manual)
12-011 Corona: minimum speed not reached

Cause Remedy
Machine speed too low to switch on
Increase machine speed
corona.

7. TROUBLESHOOTING
12-012 Corona: suction air speed low

Cause Remedy
Ozone extraction unit is switched off Switch on ozone extraction unit
• Check extraction tubes and clean if
Extraction tubes are blocked necessary
• Empty receptacle.
• Clean the flow sensor
Flow sensor is soiled or defective • Check wiring, if necessary replace the
flow sensor
12-014 Corona: Electrodes not in production position

Cause Remedy
The electrodes were pivoted in but did not
Check sensor settings
reach their limit position.
12-015 Corona: station ready for operation

12-016 Corona: Frequency converter standby mode
12-017 Corona: capacitors not discharged
12-018 Corona: station working
Cause Remedy
Operating message -
12-021 Corona: temperature prewarning

Cause Remedy
The temperature of the frequency
converter did not reach the warning See Chapter 7.14.3
threshold.
12-022 Corona: maximum power exceeded

Cause Remedy
The selected power is too high for the
Reduce power
station.
12-023 Corona: power has fallen below minimum

Cause Remedy
The selected power is too low for the
Increase power
station.

7. TROUBLESHOOTING
7.7 Alarm group 19 - General 1
19-000 EMERGENCY STOP pressed

Cause Remedy
19-002 Thermocouple, printing machine hydraulic system

19-003 Drying system blower overtemperature
Cause Remedy
19-004 Drying system safety temperature monitor

Cause Remedy
Heating registers of the drying system are
Check the heating registers
too hot
19-006 Drying system overtemperature

Cause Remedy
The temperature of the drying system is
min. 10°C above the set temperature (see Wait for the system to cool down
Chapter 5.6)
19-007 Drying system undertemperature

Cause Remedy
The temperature of the drying system is
Waiting until the heating process is
min. 10°C below the set temperature (see
complete
Chapter 5.6)
19-010 Switching cabinet temperature warning

Cause Remedy
Temperature in switching cabinet is too
See Chapter 7.13
high
19-011 Compressed air below 5 bar

Cause Remedy
• Incorrect setting on the pressure
regulator Check compressed air on the
maintenance unit
• Customer's on-site supply is unstable

7. TROUBLESHOOTING
19-012 Switching cabinet temperature alarm

Cause Remedy
Temperature in switching cabinet is too
See Chapter 7.13
high
19-014 Web edge control of the unwinder not active

Cause Remedy
Activate the web edge control (see the
Web edge control is deactivated
19-015 Thermocouple, drying system blower

Cause Remedy
19-016 Infeed warning temperature

19-017 Discharge warning temperature
19-018 Infeed overtemperature
19-019 Discharge overtemperature
Cause Remedy
19-020 Motor cooling system below limit

Cause Remedy
Supply temperature low Check control valve of the cooling system
19-021 Water cooler thermocouple

Cause Remedy
Adjust the temperature of the temperature
Temperature of the temperature control
control unit to the display (see the
unit deviates from that displayed
Temperature of the temperature control
Clean and inspect the water circuit
unit is outside of the tolerance
Water cooler has failed Check water cooler

7. TROUBLESHOOTING
19-022 Print mark no longer being detected properly

Cause Remedy
Print mark error See Chapter 7.18.3
19-023 Rocker arm in the bottom position

Cause Remedy
Rocker arm downstream from the
unwinder is in the bottom position for Check the rocker arm (value must not fall
longer than 3 sec (the fabric is torn or the below 1,600 for longer than 3 sec)
bale of fabric has lost its tension)
19-025 Safety cover for printing unit 1 is open

Cause Remedy
The safety cover of the printing unit is
Close safety cover
open.
19-033 Crane motor protection

Cause Remedy
19-034 Flow volume in water cooler supply too low

Cause Remedy
• Check control valve of the cooling
system
Flow volume too low
• Check lever positions of the valves on
the cooling system
19-035 No flow in water cooler supply

Cause Remedy
No flow from the cooler Cooler switched off or defective

7. TROUBLESHOOTING
19-045 Order is complete

19-046 Order 2 is complete
Cause Remedy
• Press the <Stop> push button on the
winder and perform the roll change
The current order is complete. (see the rollFLEX PX6 technical
manual).
• Set up a new order
19-047 Corona not active during operation

Cause Remedy
Corona is deactivated Activate corona as needed
19-048 Corona open sensor not tripped

Cause Remedy
This information is only used for the
Limit switches not yet operated monitoring of the pneumatic system and
the mechanical systems.
19-049 Winder shaft not in position

Cause Remedy
Insert the winder shaft in the insertion arm
Roll diameter on the winding arm and carry out the lay in arm step on the
exceeded and no winder shaft has yet winder operating unit – move the winder
been inserted for the next roll shaft into the swivel arm (see the rollFLEX
PX6 technical manual)
19-050 Roll change pending in Unwinder 1

19-051 Roll change pending in Unwinder 2
Cause Remedy
Warning: Min. winding diameter for
Initiate roll change
unwinder reached
19-052 Corona mains voltage missing

Cause Remedy
Corona is switched off Switch corona on as needed

7. TROUBLESHOOTING
19-053 Thermostatic switch, corona extraction system

Cause Remedy
• Check motor for ease of movement
Overcurrent on the extraction system
• Check supply and exhaust air ducts
motor
• Check the motor
19-054 Corona main contactor fault during operation

Cause Remedy
Contactor defective or stuck Check contactor
19-55 Corona frequency converter fault

Cause Remedy
19-999 FATAL ERROR! No USER PARTITION on the memory card

Cause Remedy
• Create new memory card (Starlinger
technician)
User partition does not exist
• Replace memory card
(see Chapter 6.4)
7.8 Alarm group 20 - General 2
20-002 Winder EMERGENCY STOP pressed

Cause Remedy
20-003 Winder EMERGENCY STOP contact fault

Cause Remedy
Acc. to the contact monitoring system of • Establish cause

the <EMERGENCY STOP> push button, • Reset the EMERGENCY STOP (see
the two contacts do not match the rollFLEX PX6 technical manual)
Fault in the safety system See Chapter 7.17

7. TROUBLESHOOTING
20-004 EMERGENCY STOP, machine operating unit

20-006 Printing unit EMERGENCY STOP pressed
20-008 Corona EMERGENCY STOP pressed
20-010 Unwinder EMERGENCY STOP pressed
Cause Remedy
20-016 Back left safety switch pressed

20-017 Back left safety switch contact fault
20-018 Front left safety switch pressed
20-019 Front left safety switch contact fault
20-020 Front right safety switch pressed
20-021 Front right safety switch contact fault
20-022 Back right safety switch pressed
20-023 Back right safety switch contact fault
20-024 Printing unit 1 safety switch pressed
20-025 Printing unit 1 safety switch contact fault
Cause Remedy
Safety door not closed Close safety door
Safety switch is faulty See Chapter 7.17.2

7. TROUBLESHOOTING

20-036 Operating unit safety switch pressed
20-037 Operating unit safety switch contact fault
Cause Remedy
Safety door not closed Close safety door
Safety switch is faulty See Chapter 7.17.2
20-039 Winder EMERGENCY STOP light barrier

Cause Remedy
EMERGENCY STOP activated by the Establish cause, unlock <EMERGENCY
interruption of the light barrier on the STOP> push button, and reset with
winder <Reset Emergency Stop> push button
20-040 Speed monitoring system EMERGENCY STOP

Cause Remedy
Sensors on the drive side of the winder
are incorrectly adjusted or faulty (one of See Chapter 7.12.1
the two must always be lit)
20-070 Drying system extractor, motor temperature too high

20-071 Web edge control motor temperature too high
20-073 Water pump motor temperature too high
Cause Remedy
20-074 Extraction system fault

20-076 Drive fault, unwinder web edge control
20-077 Drive fault, water pump
20-078 Extraction system frequency converter warning
20-080 Unwinder web edge control motor, frequency converter warning
Cause Remedy

7. TROUBLESHOOTING
20-081 Water pump motor, frequency converter warning

Cause Remedy
20-082 Extraction system overloaded

20-083 Unwinder web edge control motor overloaded
20-084 Water pump motor overloaded
Cause Remedy
7.9 Alarm group 59 - Operating messages
59-001 Machine started

59-002 Machine stopped
59-005 Drying system on
59-006 Drying system off
59-007 Cooler on
59-008 Cooler off
59-009 Web edge control on
59-010 Web edge control off
7.10 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. number 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

7. TROUBLESHOOTING
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
7.11 Bus systems
7.11.1 Checking the X2X link bus
Fig. 4967/7001
1 Contacts for bus supply 4 X20 module side view

2 Contacts for bus data 5 X20 module BM11
3 Contacts for I/O supply 6 X20 module BM01

7. TROUBLESHOOTING
Procedure
1. Note down or export the number and text of active and historical
X2X link bus alarms (see Chapter 5.11)
2. Switch machine off and back on again after 30 seconds
3. Start the machine and observe its operating behaviour
4. Check status LEDs on the X2X link module (type X20 BR 9300)
(see the manufacturer's documentation)
- "r" lights up green: X2X link module is OK
- "r" flashes: X2X link module is faulty
- "r" does not light up: X2X link module no supply
- "X" lights up orange: X2X link communication OK
- "X" does not light up: no X2X link communication
5. Check the status LEDs on the X20 module
- "r" lights up green: X20 module is OK
- "r" flashes: X20 module is faulty
- "r" does not light up: X20 link module no supply
6. Check X2X link addressing and hardware number (addresses can only
be assigned once)
7. On the relevant menu screens, check the protocol counter and observe
the fault counter (CycleCount, BreakCount)
8. Check on the back of the X2X link module that the bus modules (5) and
(6) are properly connected
9. Check X2X link cable connection
10. Check the earthing of the machine or check it by having an earthing
measurement carried out on your premises by an authorised electrical
contractor
11. Check shielding
- Check shield connection and cable ties
- Check the shielding braid and wire for corrosion
- Check that the motor cable is shielded on both sides and that the
shielding is fully tightened (check the shield connection points for
electrical conductivity)
- Check top-hat rail for earth connection
- Check that the earth connection and the X2X link bus are attached
to the shielding plate of the frequency converter
- Check that the connections are made properly (pay attention to the
electrical conductivity of the shield connection points)
- Check analogue signal on one side (via the control module is best)

7. TROUBLESHOOTING
12. Check potential equalisation (connection of all machine components)

13. Check the earthing of peripheral I/O nodes (terminal boxes)
14. Check the cable duct
- Check that the cable duct is connected with straps, screwed into
place and earthed
- Check that the separating strips are present
- Check that the cables are routed separately
- Check that the excess cable is not routed parallel to power cables
15. Check the cable length (max. 100 m between the individual nodes)
16. If necessary, replace X2X link module
7.11.2 Checking the EPL bus connection (POWERLINK ethernet)
Procedure
1. Note down or export the number and text of active and historical EPL
bus alarms (see Chapter 5.11)
3. Start the machine and observe its operating behaviour
4. Check the status LED on the bus controller
- Lights up green: bus controller is OK
- Lights up red: bus controller is faulty
5. Check EPL addressing and hardware number (addresses can only be
assigned once)
6. Check the status of the EPL module on the corresponding menu
screens
7. Check on the back of the X20 I/O system that all EPL modules are
properly connected
8. Check the ethernet cable connection (min. CAT 5/6 with metal on the
connector)
9. Check the earthing of the machine or check it by having an earthing
measurement carried out on your premises by an authorised electrical
contractor
10. Check shielding

7. TROUBLESHOOTING

- Check that the earth connection and the EPL bus are attached to the
shielding plate of the frequency converter
- Check analogue signal on one side (via the control module is best)
11. Check potential equalisation (connection of all machine components)
12. Check the earthing of peripheral I/O nodes (terminal boxes)
13. Check the cable duct
- Check that the cable duct is connected with straps, screwed into
place and earthed
- Check that the separating strips are present
- Check that the cables are routed separately
- Check that the excess cable is not routed parallel to power cables
14. Check the cable length (max. 100 m between the individual nodes)
15. If necessary, replace the EPL module
7.12 Sensors
7.12.1 Checking proximity switches

Inductive proximity switches (e.g. limit switches) 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).
Every sensor has a given detection area for steel, which is reduced by half with
aluminium or brass. The accuracy of the signal depends on the positioning of the
sensor and any fine adjustment.
Procedure
1. Check sensor for mechanical damage
2. Check the switching distance (see the manufacturer's documentation)
3. Reposition the sensor if necessary
- Unplug connector
- Undo nut (sensor is freed)
- Set the distance between the sensor and the object with a feeler
gauge
- Check the connector

7. TROUBLESHOOTING
- Tighten the nuts (see manufacturer's information for tightening

torques)
- Check function
4. Trigger the sensor with a suitable object and check the LED on the
control system input (see the Circuit diagram)
5. Check power supply
6. Check wiring
7. Measure output signals
8. If necessary, replace the sensor
 If the new sensor does not function, replace the input card
7.12.2 Checking the pressure sensor

A pressure sensor converts the physical pressure variable (force per area) into
an electrical output variable as a dimension for the pressure.
Procedure
1. Check the sensor for mechanical damage, particularly the diaphragm
3. Measure the output signals and check the value on the display
4. Check parameters or DIP switch setting (addressing) (see the Circuit
diagram)
5. Check wiring
6. Check the plug connections
- If the new sensor does not function, replace the input card
7.12.3 Checking the thermocouple

The thermocouples are used to measure temperatures. At the free ends of the
two connected conductors, if there is a temperature difference along the
conductors, an electrical voltage is generated due to the Seebeck effect.
The connection point for the two conductors must also have a different
temperature than the reference point. The receiver modules provide automatic
temperature compensation to adapt to the ambient temperature. This makes
calibration unnecessary on these thermocouples.
The connection is made via a terminal head or a compensating line made of one
of the following alloys (acc. to IEC 751 or EN 60751):

7. TROUBLESHOOTING
Type Colour coding acc. to IEC Alloy

Green
K NiCr-Ni
White
Black
J Fe-CuNi
White
Type Colour coding acc. to EN Alloy

Red
L Fe-CuNi
Blue
To avoid deviations in the measured values from thermocouples

• The terminal units must be made from the same alloy as the
compensating lines
• No cable end sleeves may be used on compensating lines
Procedure
2. Adjust the spring on the bayonet coupling so that the sensor is pushed
against the surface being monitored
3. Check and tighten terminal connections where required, observe
polarity
4. Check wiring
5. Check sensor:
- For sensors with a connecting head, disconnect and twist the
connection line
- For potted sensors, connect a new sensor or a twisted
compensating line to the input
 The ambient temperature is displayed on the screen:
The sensor is faulty.
 The ambient temperature is not displayed on the screen:
The control unit input is faulty.
- If the new sensor does not function, replace the temperature control
or input card

7. TROUBLESHOOTING
7.12.4 Checking the light sensor

A light sensor registers the light signal sent out by it and reflected back by an
object. The quality of the signal is dependent upon the properties of the object
being detected and the condition of the sensor.
Procedure
1. Clean sensor
3. Position the sensor
 The red measurement point must not be interrupted by machine
parts.
 The sensor must be positioned such that the material being detected
(e.g. fabric) is located in the centre of the detection area.
4. Remove any obstacles from the detection area of the sensor
6. Measure output signals
7. If necessary, replace the cable
- If the new sensor does not function, replace the input card
7.12.5 Checking the light barrier

A light barrier registers the interruption of a light beam by an object. Light barriers
exist in the following two types:
• Through-beam light barriers: with a transmitter and receiver
• Reflection light barriers: with a transmitter and reflector
Procedure
1. Check the transmitter and receiver or reflector for mechanical damage
2. Clean the transmitter and receiver or reflector
4. Measure output signal
5. Check the alignment of the transmitter to the receiver or reflector
6. Replace the reflector with another of the same type
7. If necessary, replace the cable
8. If necessary, replace the transmitter and receiver or reflector
- If the new transmitter or receiver does not function, replace the input
card.

7. TROUBLESHOOTING
7.13 Switching cabinet air conditioning

A cooling system is built in to prevent overheating of the switching cabinet. If a
temperature of 55°C is exceeded in the switching cabinet, an alarm is displayed
as a warning. If the temperature exceeds 65°C, an alarm is displayed and the
machine is switched off.
7.13.1 Inspecting the switching cabinet with fan
Procedure
1. Clean the fan filter and replace if necessary (only with filter material of
the same properties)
2. Check the circulation of the fan
 The cold air must be taken in by the fan unimpeded, passed through
an air filter, and blown into the switching cabinet.
 The hot air must be able to escape unimpeded through the air filter
at the air outlet.
3. Inspect the fan in the switching cabinet and replace if necessary
4. Close the switching cabinet door
7.13.2 Inspecting the switching cabinet with heat exchanger

On switching cabinets with air/water cooling, the heated air inside the cabinet is
taken in by a fan and passed through a heat exchanger. The heat is absorbed
with the water acting as the cooling medium, and then discharged by a water
return line. The heat exchanger is only operational if the switching cabinet doors
are closed.
NOTE!
The water supply line and return line must not be mixed up during
installation!
The condensate drain must be installed in accordance with the

7. TROUBLESHOOTING
NOTE!
Possibility of damage to the electronic components through
condensation!
• Keep the switching cabinet doors closed at all times!
• Keep the seals in the proper condition!
• Check condensate drain on a monthly basis for blockage and
clean as necessary
The switching cabinets are provided with seals to prevent the
discharged hot air from one getting in another switching cabinet.
The moisture in the discharged hot air results in increased
condensation during cooling. If a large amount of condensate
collects in the drop pan, it could be taken up by the fan, and result
in serious damage to electronic components.
Procedure
1. Close the switching cabinet door
2. Open the cooling water line
3. Clean the filter in the cooling line
4. Check the supply temperature at the cooling unit input, and reduce if
necessary
5. Inspect the cooling unit, if necessary set the temperature to 35°C
6. Inspect the fan in the switching cabinet and replace if necessary
7. Inspect the valve in the cooling unit and replace if necessary
8. Increase the flow volume on the water distributor
9. Reduce the ambient temperature
7.14 DC drives
7.14.1 Checking the DC drive for overheating
Procedure
1. Allow motor to cool down
2. Check mechanism for ease of movement
3. Check gearbox and maintain as necessary
- Check the oil level
- Check the bearing

7. TROUBLESHOOTING
4. If a motor fan is fitted:

- Check if the fan cover is dirty, and clean if necessary
- Check that the fan blades are intact, and replace if necessary
5. If the motor is soiled, clean the following parts:
- cooling fins
- if applicable, the filter
6. Check if the ambient temperature is too high
7. Check the machine parameters
7.14.2 Determining the cause that triggered the motor protection
Procedure
1. Compare set current value on the triggering device with the value on the
motor type plate
3. Check cable connection
4. Check motor temperature
- Check the bearing
7. Check direction of rotation
8. Check the motor for short-circuit/short-circuit to earth and other
malfunctions
9. Perform maintenance (see the manufacturer's documentation)
7.14.3 Checking the frequency converter
Procedure
1. Note down the alarm number and reset the alarm (see Chapter 5.11)
 This activates the reset input on the frequency converter.
2. Check the diagnostics menu for of the drive
4. Check wiring
5. Look-up the fault displayed on the frequency converter in the
manufacturer's documentation

7. TROUBLESHOOTING
7. Perform the following measurements on the frequency converter:

- Input and output voltage
- Set value specification for speed
- Enable signal, forwards/backwards
- Ready for operation signal
- Signal mode
- Signal fault
- Actual current value output
8. Check the bus connection
9. Compare programming
malfunctions
11. Check parameters
12. Shut off motor and switch on again
 If the fault occurs even without the motor: replace the frequency
converter
 If the fault does not occur without the motor: check the motor
7.15 Stepper motors
7.15.1 Checking a stepper motor after overheating
Procedure
7.15.2 Checking the stepper motor module
Procedure
1. Check the power supply on the stepper motor module and on the bus
node in question (see Chapter 7.18.5)
2. Check cable connections for the stepper motor and stepper motor
module against the Circuit diagram
3. Check that the models installed correspond to those listed in the Circuit
diagram
4. If necessary, replace the stepper motor module

7. TROUBLESHOOTING
7.15.3 Stepper motor module is referenced incorrectly
Procedure
1. Check the stepper motor module
2. Check that the models installed correspond to those listed in the Circuit
diagram
3. Check mechanical components
4. Move the stepper motor manually
5. Re-reference the stepper motor module
For further information, see the manufacturer's documentation.
7.16 Servo drives
7.16.1 Checking the servo converter for overheating
Procedure
1. Check temperature of the servo converter
2. Reset the alarm (see Chapter 5.11)
3. Ensure that there is an adequate airflow across the heat sink
4. Check the heat sink for dirt (dust) and clean as necessary
5. Check the cooler fan for proper functioning (noise)
6. Check switching cabinet air-conditioning (see Chapter 7.13)
7. Check drive components for ease of movement
7.16.2 Checking the servo motor for overheating
Procedure
- Check the bearing
4. If the motor is soiled, clean the following parts:
- cooling fins
- if applicable, the filter

7. TROUBLESHOOTING
5. Check if the ambient temperature is too high

6. Check the machine parameters
7.16.3 Checking the servo converter
Procedure
1. Check the machine for jams
2. Note down the alarm number and alarm text incl. the following fault
numbers of the servo drive and reset the alarm (see Chapter 5.11)
3. Run machine until empty
5. Check mains supply
6. Check fuse, motor cable, rotary encoder cable and bus cable
7.16.4 Checking the servo motor
Procedure
1. Note down the alarm number and alarm text, and reset the alarm (see
Chapter 5.11)
2. Check drive elements for ease of movement (if necessary, eliminate
jams and check brakes)
6. Check the plugged connections for the motor cable and rotary encoder
7. Replace the motor cable or rotary encoder cable
8. Uncouple the load (disconnect the coupling) and test in idle operation
malfunctions
7.16.5 Checking the servo converter for a phase failure
Procedure
2. Test fuses
3. If applicable, check the contactor
4. Check wiring
5. Check servo converter (see Chapter 7.16.3)

7. TROUBLESHOOTING
7.16.6 Checking the rotary encoder
Procedure
1. Note down the alarm number and alarm text, and reset the alarm (see
Chapter 5.11)
2. Check cable connection
3. Remove the plugged connections in a de-energised state and reconnect
4. Press the <EMERGENCY STOP> push button
5. Turn the motor by hand and observe the status LEDs on the expansion
card of the servo inverter (see the manufacturer's documentation),
 depending on the direction of rotation a certain status LED must light
up.
6. Check shielding
- Check that the earth connection is attached to the shielding plate of
the frequency converter
7. If necessary, replace the cable of the rotary encoder
8. If necessary, replace the expansion card
9. If necessary, replace the motor
7.16.7 Checking for a lag error
Procedure
1. Check the machine for jams or material fragments
2. Check the machine components for ease of movement
3. Reset the alarm (see Chapter 5.11)
6. On the menu screen of the drive in question, observe the rocker arm
position
7. Check the drive for rotary encoder faults (see Chapter 7.16.6)

7. TROUBLESHOOTING
7.17 Fault in the safety system
DANGER!
Risk to life from the failure of the safety system!
Have the condition and function of all components and functions
of the safety system checked once a month by an electrician.
7.17.1 Checking safety control X20SL8000
Fig. 4967/7002
1 Ethernet POWERLINK interface 8 Node numbers switch

2 Safety processor Status LEDs of the safety
processor
Slot for program memory 9
3 (SafeKEY) / SafeKEY unlocked / • FAIL
SafeKEY locked • SKEY

7. TROUBLESHOOTING
2x RJ45 ports for ethernet

4
POWERLINK
Terminal blocks for SafeLOGIC Status LEDs of the safety
5 processor
supply
Integrated power supply unit • R/E
10
with status LED for power • ENTER
supply • MXCHG
6
• Lights up green: supply • FW-ACKN
present
• Not lit: supply not present
Status LEDs of the ethernet 11 <Select> switch
POWERLINK interface
7 • STATUS
• L/A IF1 12 <Confirm> push button
• L/A IF2
The term "ethernet POWERLINK" is shortened to "EPL" in the following.

7. TROUBLESHOOTING
Status LEDs of the safety processor (10)
Label Status Description

Not lit Startup phase
Lights up green Application is present and being executed
Application is present but not being executed
R/E ("Automatic start" not selected in the Download
Flashes green dialog of SafeDESIGNER, or startup phase is
active and not all of the required safe modules
have been properly configured on the network.)
Flashes orange quickly There is no application on the SafeKEY
Lights up green Absence of authorisation
Flashes 1x for 0.8 s Confirmation of correct entry
ENTER
Flashes at 1 Hz for 5
Operating error
secs
Not lit orange Module configuration OK
Replacement of a module detected
Replacement of 2 modules detected
MXCHG Replacement of 3 modules detected
Replacement of 4 modules detected
Replacement of more than 4 modules detected
Absence of a module detected

Not lit Firmware configuration OK
FW-ACKN Flashes orange Firmware update in progress
Lights up orange SafeKEY was replaced
ENTER Light up in a continuous • Module scan is in progress or is in the
MXCHG sequence: green - orange startup phase (from Release 1.5)
FW-ACKN - orange • Check status LEDs of the EPL interface (7)
Status LEDs of the safety processor (9)
DANGER!
Risk to life from the failure of one of the modules in the safety
system ("F A I L" LEDs are permanently lit).
Replace the defective module immediately and initiate all of the
necessary repair measures straight away.

7. TROUBLESHOOTING

Does not light up red Operational state
F
Boot phase, loading the firmware, status if the
A F I L
SafeKEY is absent
I
Complete HW test (max. duration approx. 5
L F A I L
secs)
F A I L Initialisation and startup of the firmware
(lit,
L Preoperational state
lit bright)
F A I L Fail-safe state applicable to whole module
Not lit No access to the SafeKEY
SKEY
Flashes orange Access to the SafeKEY
Functions of the <Select> switch (11)
Position Function Description

Confirmation of a firmware update to one or
FW-ACKN Firmware acknowledge
more modules
SK-XCHG SafeKEY exchange Confirm replacement of the SafeKEY
SK-COPY SafeKEY copy Copy the configuration data from the SafeKEY
SCAN Scan Trigger a module scan
TEST Test Perform an LED test
Confirm replacement of 1, 2, 3, 4 or more than
1, 2, 3, 4, n Module replacement
4 modules

7. TROUBLESHOOTING
Status LEDs of the ethernet POWERLINK interface (7)

The EPL interface is not supplied with power, or
is in "NOT_ACTIVE" status (for approx. 5 secs
after each restart). No communications are
possible. If an EPL communication is detected
Not lit
within these 5 secs, the EPL interface switches to
the status "PRE_OPERATIONAL_1" (single
flash). Otherwise status "BASIC_ETHERNET"
(flashing).
Lights up green The EPL interface is in status "OPERATIONAL".
The EPL interface is in a fault status (failure of
ethernet frames, accumulation of collisions on
Lights up red the network, etc.). The red flashing signals
immediately after switch-on are not an indication
of faults.
The EPL interface did not detect any EPL
communication. In this state it is possible to
STATUS Flashes green at communicate with the EPL interface directly via
approx. 10 Hz UDP. If during this state an EPL communication
is detected, the EPL interface switches to the
status "PRE_OPERATIONAL_1" (single flash).
The EPL interface is in status
"PRE_OPERATIONAL_1". The CN (Controlled
Single flash at approx.
Node) waits to receive an SoC frame and then
1 Hz
switches to status "PRE_OPERATIONAL_2"
(double flash).
"PRE_OPERATIONAL_2". In this status the EPL
interface is normally configured from the
Manager. Then a command is issued to switch to
Double flash at approx.
the status "READY_TO_OPERATE" (triple flash).
1 Hz
The switch to the next status does not occur if,
for example, an incorrect node number is set or
the module is deactivated in the "B&R
Automation Studio".
Triple flash at approx. "READY_TO_OPERATE". The Manager issues a
1 Hz command to switch to the status
"OPERATIONAL".
STATUS The EPL interface is in the status "STOPPED".
Output data is not output and no input data is
Flashes at approx.
supplied. This status can only be obtained and
2.5 Hz
switched away from with an appropriate
command from the Manager.

7. TROUBLESHOOTING
Testing LEDs
1. Set <Select> switch to "TEST"
2. Press the <Confirm> button
 All LEDs of the safety processor (left-hand and centre module of the
SafeLOGIC) remain lit while the respective button is being pressed.
On releases < 1.4, the "SKEY" LED does not light up for this test.
Slot for program memory (SafeKEY) (3)

To operate the SafeLOGIC, a program memory (SafeKEY) is needed to save the
program, the parameters, and the system configuration. The SafeKEY is
equipped with a mechanical lock, to make it harder to pull out unintentionally
during operation.
DANGER!
Danger to life from electric current!
Work on the safety system must only be carried out by trained
electricians! Safety measures for work on electrical components
must be adhered to!
DANGER!
Risk of life from the failure of the safety system after the SafeKEY
is removed!
Pulling out the SafeKEY during operation causes the SafeLOGIC
to restart, switches off all safety-related actuators, and may result
in the destruction of the data on the SafeKEY.
The SafeKEY must not be pulled out during operation!
NOTE!
Possible damage to property due to the use of non-original
replacement parts!
Only a SafeKEY from the original manufacturer may be used.
Replacing the SafeKEY

2. Unlock and remove the old SafeKEY
3. Insert a new SafeKEY and lock
4. Switch on the machine and wait until it is ready for operation
5. Confirm replacement on the SafeLOGIC: Select the "SafeKEY
Exchange" function and confirm
6. Check all functions of the safety system
 Replacement of the SafeKEY is complete.

7. TROUBLESHOOTING
Selecting the function and confirming

1. Move the <Select> switch to the position for the desired function
2. Press and hold the <Confirm> push button for 0.5 - 5 secs
 If the Confirm push button is released before 0.5 secs, it has no
effect.
 After 0.5 secs, the "ENTER" LED on the safety processor starts to
come on.
 When the push button is released, the "ENTER" LED remains lit for
another 0.8 secs to indicate that the input was correct.
 If the push button is held for longer than 5 secs, the "ENTER" LED
flashes for 5 secs, thereby indicating an operating error. Another
possible reason for an operating error is an inappropriate position of
the <Select> switch.
 The confirmation of an action can take up to 5 mins. No button must
be pressed during this period!
Replacing SafeIO modules or the SafeLOGIC
DANGER!
Danger to life from electric current!
Work on the safety system must only be carried out by trained
electricians! Safety measures for work on electrical components
must be adhered to!
NOTE!
Possible damage to property due to the use of non-original
replacement parts!
Only a SafeIO module or a SafeLOGIC safety control from the
original manufacturer may be used.
The SafeLOGIC automatically detects the replacement of safe modules. After the
module change, the overall system (SafeLOGIC, openSAFETY) automatically
ensures that the module is operated again with the correct parameters and that
incompatible module types are rejected. Therefore after the module replacement
the following potential faults remain:
• Transposing the terminals between the different modules
• Wiring fault
• Transposing SafeIO modules

7. TROUBLESHOOTING
Replacement of a SafeLOGIC occurs in the same way as a normal module

replacement. As a rule, when a SafeLOGIC is replaced, the SafeKEY must be
carried over from the replaced SafeLOGIC, to avoid the activation of an outdated
safety application.
Procedure
2. Pull the terminals out of the defective modules
3. Remove the modules (see the manufacturer's documentation)
4. Install new modules
5. Connect the terminals
6. If more than 1 module or the SafeLOGIC is replaced: test wiring
7. Switch on the machine and wait until it is ready for operation
8. Confirm replacement on the SafeLOGIC: Select the "Module
replacement" function (position acc.to number of modules replaced)
and confirm
9. Check all functions of the safety system
 Replacement of the modules is complete.
If several modules are replaced simultaneously, or the

SafeLOGIC, suitable wiring tests must be used to check the safety
function and to detect terminals transposed between the modules
with certainty. Check all safety functions!
7.17.2 Checking the safety switch
DANGER!
The safety switch of safety devices may never be bypassed in
order to get rid of an alarm!
Procedure
• Check if one or more safety doors are open, and if necessary close
• Check settings (switching distance) of the safety switches
• Check parallelism, height and lateral offset
• Check proper functioning of safety switch
• Check wiring of the safety switch for damage
• Check if the wiring to the safety control is broken
• Check LED for the safety circuit

7. TROUBLESHOOTING
7.17.3 Checking for partial actuation of the safety door circuit

The status changes for all switch contacts of the component are monitored for
simultaneity. If one of these status changes does not occur simultaneously
(outside of the discrepancy time), there is a partial actuation.
Procedure
• Properly close the safety door
• Check the status of the safety control and of the respective input card
(depending on the switch type, one or both channels of the safety door
circuit must logic “1” for a closed safety door, and logic “0” for an open
safety door (see the Circuit diagram))
• Check the switching distance of the safety switch
• Lateral and height offset: adjust active areas of the safety switch and
actuator so that they are parallel and opposite one another
• Check the safety switch (see Chapter 7.17.2)
• Check wiring for damage and check against the Circuit diagram
• Perform a functional test of the safety doors
7.17.4 Checking for a cross-circuit in the safety door circuit

A pulsed signal must be assigned to the input of the safety control. If there is a
signal at this input other than the defined signal, there is a cross-circuit.
Procedure
• Check the status of the safety control and the respective input card
• Check wiring for damage and check against the Circuit diagram
• Perform a functional test of the safety doors
7.17.5 Checking the earth or short-circuit of a pulse output
Procedure
1. Check wiring against the Circuit diagram
2. Check the safety switch (see Chapter 7.17.2)
3. Check the safety components
4. Contact the Customer-Service Center

7. TROUBLESHOOTING
7.18 Machine-specific tests
7.18.1 Checking the <Stop> push button
Procedure
1. Check <Stop> push button for mechanical damage
2. Check cables of the Stop loop against the Circuit diagram
 <Stop> push buttons are normally not actuated when closed.
3. If necessary, replace the <Stop> push button
7.18.2 Checking the web edge control
Procedure
• Check the movement of the unwinder with the manual adjustment
movement
• Activate the web edge control
• Perform material alignment
• Check settings against the Circuit diagram, correct if necessary
• Read the display of the control unit in question (see the manufacturer's
documentation)
7.18.3 Print mark error

If more than 10 print marks are not detected on the main fabric, this may be
caused by the following:
• Poor print quality (print mark too thin, distance to printing too small and
inadequate contrast between fabric colour and print mark colour)
• Distance between print marks does not match the set section length
• Slipping at discharge
• Web edge control has failed
• Sensors are poorly calibrated (contrast)
In order to rectify faults, proceed as follows:

• Check the print mark settings (see the rollFLEX PX6 technical manual)
• Adapt the section length to the fabric being used
• Check the settings of the web edge control (see the rollFLEX PX6
technical manual)

7. TROUBLESHOOTING
• Carry out the colour comparison again (see the rollFLEX PX6 technical
manual)
• Check the sensors (see the manufacturer's documentation)
7.18.4 Limit position fault

• Check the position of the roll of fabric on the expansion shaft
• Check the position of the web edge sensor
• Check that the fabric is running through the web edge sensor
• Check light barrier (see Chapter 7.12.5)
7.18.5 Checking the control voltage

The 24V control voltage is a stabilised, short-circuit proof DC voltage.
Procedure
1. Measure voltage at the power supply unit
- Typical tolerance range: 23 - 25 V DC
- For deviations from the tolerance range: Check the size of the input
voltage, if necessary adjust the power supply unit
2. Check the LED on the power supply unit
- Lights up red: Defect or short-circuit
3. Check the functional ability of the buffer module and replace if
necessary
4. Check the line safety switch in the switching cabinet against the Circuit
diagram
5. Check the consumers individually:
- Switch off all consumers with the 24V line safety switch
- Measure voltage at the power supply unit
- Switch the consumers back on again one at a time, until the voltage
fails again
- On the line safety switch in question: Check the consumer against
the Circuit diagram, replace defective consumers

8. ENCLOSURES
NOTES
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USER MANUAL

Doc. no.: DBE- 04967 Language: English

Warranty and liability

rollFLEX PX6 display DBE-04967 PAGE 2 / 153

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

rollFLEX PX6 display DBE-04967 PAGE 3 / 153

5.3 “Corona pre-treatment unit” submenu ................................................................ 38

rollFLEX PX6 display DBE-04967 PAGE 4 / 153

6.4 Changing the memory card ................................................................................ 93

rollFLEX PX6 display DBE-04967 PAGE 5 / 153

7.16.6 Checking the rotary encoder .................................................................... 141

rollFLEX PX6 display DBE-04967 PAGE 6 / 153

ABOUT THIS DOCUMENT

Notation Representation Example

rollFLEX PX6 display DBE-04967 PAGE 7 / 153

Indicator word Meaning

rollFLEX PX6 display DBE-04967 PAGE 8 / 153

General warning: risk of injury

General notice: potential damage to property

Reference to further information

Terms and abbreviations

rollFLEX PX6 display DBE-04967 PAGE 9 / 153

1.2 Ambient conditions

For further information on the control panel, see the

rollFLEX PX6 display DBE-04967 PAGE 10 / 153

2 COMPONENTS AND INTERFACES

2.1 Communications interfaces

2.2 Control panel

For a detailed description of all the components of the control

Malfunctions or damage to property due to faults resulting from

rollFLEX PX6 display DBE-04967 PAGE 11 / 153

3 CONTROLS AND DISPLAY ELEMENTS

3.1 Control panel

For a detailed description of all the control and display elements

3.2 User interface

rollFLEX PX6 display DBE-04967 PAGE 12 / 153

4 BASIC INFORMATION ON OPERATION

4.1 Readiness for operation

Graphical user interface

The graphical user interface is dynamic and reflects the particular

rollFLEX PX6 display DBE-04967 PAGE 13 / 153

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

rollFLEX PX6 display DBE-04967 PAGE 14 / 153

4.2.2 Virtual keyboard

Delete input value

Cancel input and close virtual keyboard

4.2.3 Virtual navigation bar

Jump to the first / last entry

Jump to the first / last visible entry

Scroll upwards / downwards

Close navigation bar

rollFLEX PX6 display DBE-04967 PAGE 15 / 153

4.3 Layout of the graphical user interface

1 Status area 2 Working area

4.3.1 Status area

Selected authorisation level

rollFLEX PX6 display DBE-04967 PAGE 16 / 153

“Alarm management” indicator

“Selected authorisation level” indicator