HHS Vision Manual S

Manual
XTS²-Xcam PF AM
Stand-alone
10328260 XTS²-Xcam PF AM
Date: 25.11.2014
ENGLISH (Translation of the original instructions)
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Stand-alone
All Baumer hhs operating instructions and manuals are protected by copyright.
Copying, duplication, translation etc. are expressly prohibited.
Additional copies of this manual are available from the manufacturer. The
manufacturer makes no claims regarding the accuracy of the contents of this
manual.
We reserve the right to make changes at any time without giving notice in
advance.
is a registered trademark of Baumer hhs GmbH

(international registration 915310)
© 2014 Baumer hhs GmbH

Adolf-Dembach-Straße 19
D-47829 Krefeld
Tel.: +49 21 51 - 44 02-0

E-mail: [email protected]
Internet: www.baumerhhs.com
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Table of contents
1. Introduction ................................................................ 7
General notes .................................................................................... 7
CE declaration..................................................................................... 7
Notes on the documentation................................................................ 8
♦ Care when reading ......................................................................... 8
Clarification of Warning Instructions ............................................... 9
2. Safety Instructions................................................... 11
Safety provisions of general validity ..............................................11
Intended use .....................................................................................12
Using the machine..............................................................................12
Perfect technical condition..................................................................12
Equipment ..........................................................................................13
♦ Cleaning agents .............................................................................13
Modifications forbidden ......................................................................13
National laws and regulations .............................................................13
Personal protective equipment ...........................................................13
Personnel qualifications .....................................................................14
Improper use ....................................................................................15
General operator duties ...................................................................16
Life phases of the machine / operating modes ..............................17
Safety requirements .........................................................................18
General ..............................................................................................18
Safety during transport, assembly and commissioning .......................18
♦ Pictograms.....................................................................................19
Safety during production ....................................................................19
Safety during maintenance, repairs ....................................................20
Safety during disassembly and decommissioning ..............................21
Personal Protective Equipment ..........................................................22
4. Description of the System ....................................... 23
Technical description ......................................................................24
Functional Description of Xtend² Series..............................................24
8. Quality Assurance ................................................... 25
Technical description ......................................................................25
Xtend² Folding machine .....................................................................25
Camera module function ....................................................................26
Technical data camera module ..........................................................27
Technical Data display XTS² VGA BG-15“ .........................................28
Transport and Assembly .................................................................29
Connections – ‘CODE & CAM’ glue monitoring module ......................29
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Handling and Operation ...................................................................31

♦ Home .............................................................................................31
Operating Elements Xtend² ................................................................35
♦ Header Symbols ............................................................................38
♦ Camera side operating elements ...................................................39
♦ Orientation in Menu .......................................................................43
Initial Operation Controller ..................................................................44
♦ Basic Software Settings .................................................................44
♦ Offset and Start sensor connection ................................................45
Glue Pressure ....................................................................................46
Commissioning: camera module ........................................................46
♦ Setting the offset and assigning the light barriers ...........................46
♦ Camera image parameter settings .................................................47
♦ Setting of aperture and focus .........................................................48
System Settings .................................................................................49
♦ Language and Time settings ..........................................................49
♦ Inputs and Outputs ........................................................................50
♦ Encoder .........................................................................................53
♦ Connections...................................................................................56
♦ Setting up Labelling .......................................................................57
♦ Minimum Distance between Camera and Ejector...........................59
♦ Service ..........................................................................................60
User Rights ........................................................................................62
♦ Example for Pattern Search ...........................................................64
♦ Camera – Code Inspection ............................................................65
♦ Setting Up Code Inspection ...........................................................67
♦ Typical Errors during Code Inspection ...........................................68
♦ Short instructions: code reading.....................................................69
♦ Recommendations on the code creation ........................................71
♦ Code Structure ..............................................................................71
♦ Code bars and gaps width .............................................................72
♦ Bars height ....................................................................................74
♦ Colors ............................................................................................74
♦ Registration triangle .......................................................................74
♦ Position on a product .....................................................................75
♦ Code Creation Software.................................................................75
♦ Degree of Quality and Code Verification ........................................76
♦ General..........................................................................................76
♦ Classification Table........................................................................76
♦ Bar Control Examples ....................................................................78
♦ Camera – Pattern Recognition .......................................................80
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♦ Setting Up Pattern Control .............................................................81

♦ Typical pattern recognition errors: ..................................................83
♦ Camera – Blind Print Page Control ................................................84
♦ Setting Up the Blind Print Page Control .........................................85
♦ Typical Errors during Blind Print Page Control ...............................86
♦ Camera – Text Recognition (OCR) ................................................87
♦ Setting Up Text Recognition ..........................................................88
♦ Limitations during Text Recognition ...............................................90
Statistics and Production Data........................................................91
♦ Statistics ........................................................................................91
♦ Keys in the PDF Menu ...................................................................93
♦ Production Data Acquisition ...........................................................95
♦ Network connection .......................................................................95
♦ Error History ..................................................................................96
Error Detection .................................................................................97
Device can not be started ...................................................................97
You can not modify some parts on screen ..........................................97
Guns operate in test mode, but do not in production ..........................97
Only every second product is glued ....................................................97
Glue errors occur at high speed .........................................................98
Controller does not save glue pattern .................................................98
Camera system troubleshooting .........................................................99
Diagnosis .........................................................................................100
Cleaning and care ..........................................................................102
Spare Parts Controller ...................................................................103
Spare parts basic cabinet .................................................................103
Spare parts camera set TXG03 ........................................................105
Spare parts : connection set display XTS2 ALU DVI 5m...................106
Electrical Circuit Diagram ..............................................................107
10. Appendix .............................................................. 109
Warranty and Repairs ....................................................................109
Warranty ..........................................................................................109
Repairs.............................................................................................109
Baumer hhs - Adhesive application with a proven systems .......110
Alphabetical Index..........................................................................111
Contact / Kontakt............................................................................112
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1. Introduction
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1. Introduction
General notes
The machine you purchased XTS²-Xcam PF AM Stand-alone has been
designed in accordance to the latest state-of-the-art and recognised safety
regulations.
However, hazards may be posed to the life and limb of operating personnel or
third persons. Damages may occur to the machine and other material assets
(e.g. products, production buildings, etc.)
Always use the machine in compliance with this operating manual while
keeping safety and potential dangers in mind!
Eliminate faults immediately, especially those that pose a risk during

operation!
WARNING :
To prevent electric shock unplug the systems before dismantling or
service!
This controller fulfills the requirements of the:
- Machines guide-line
- Low voltage guide-line
- EMC - guide-line
This controller is provided with the CE mark.
CE declaration
The CE mark and EU Declaration of Conformity are only valid so long as the
system is used in the condition as supplied by the manufacturer. The CE mark
becomes invalid if modifications are made to safety-related parts of the product
or if auxiliary devices are incorporated. Any requests for modifications must be
agreed with Baumer hhs in writing and approved by Baumer hhs.
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1. Introduction
Notes on the documentation

As a machine operator and part of the assembly personnel, you must have read
and understood the instruction manual pertaining to the device and the relevant
documents before starting to work with the system.
You must have read and understood the documentation supplied with assembly
units produced by other manufacturers. These instructions are part of the
technical documentation.
This operating manual is a part of the machine.

- Retain the documentation for future use.
- If you resell the machine, the documentation must be passed on to the new
owner.
♦ Care when reading
Read all chapters of the operating manual carefully. Contact Baumer hhs
immediately if you have any questions of understanding.
Equip machine personnel who do not understand or do not sufficiently
understand the language of the operating manual with a version in their own
language.
Such documentation can be obtained from Baumer hhs against reimbursement of
costs.
In the event of ambiguities in the translation, the original operating manual in
German must be referred to for clarification. This is identified by "Original" on the
title page.
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1. Introduction
Clarification of Warning Instructions
Clarification of the warning and information instructions used.

Hierarchy of the warning instruction declarations:
HAZARD highest priority, when not followed: certainly danger of injury

WARNING! when not followed: injury possible
ATTENTION when not followed: remaining risk of injury and / or material damage
PLEASE NOTE when not followed: material damage possible
INFO Supplementary information
ATTENTION!
EXPLOSION HAZARD
ELECTRICAL EQUIPMENT
DANGER !
Do not look directly in the laser beam.
It might damage your eye.
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1. Introduction
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2. Safety Instructions
Safety provisions of general validity
To ensure safe and proper operation only hhs staff and other qualified
personnel may install, operate and maintain the system.
Work may only be entrusted to persons who are:
- Over the age of 18

- Qualified to carry out such work through their professional training and
experience
- Know the relevant safety and accident prevention regulations
- Have studied and understood these operating instructions carefully
The particular safety and accident-prevention regulations applying for

specific cases are to be observed.
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Intended use
CAUTION!
The machine must not be used inappropriately.
The specifications for the range of application can be found in the "Technical
data" section.
Using the machine
This system may only be used for the areas of application listed below:
• gluing
• glue control
• monitoring of quality assurance requirements
RISK OF EXPLOSION!
Never use materials containing solvents.
INFO:
Any other further application or use is deemed improper and will result in
release from all liability and from the warranty.
Perfect technical condition

For safety reasons, the system and associated assembly units produced by other
manufacturers may only be operated in a perfect technical condition. In the event
of faults or unusual behaviour of assembly units, the cause must be identified
immediately and the fault must be eliminated before restarting operation of the
assembly units.
At regular intervals, and particularly after maintenance work, check whether all
safety equipment and warning devices on the system and associated assembly
units are mounted and function properly.
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Equipment
♦ Cleaning agents
Only use cleaning agents that are provided for the scheduled cleaning.
A safety data sheet must be available for all cleaning agents. This safety
data sheet must be read and understood before handling the cleaning
agents. Suitable personal protective equipment provided by the
manufacturer must be available and used.
Before using cleaning agents, check whether they can cause damage to the
machine part that needs to be cleaned.
(Information on the flash point can be found on the safety data sheet)
Modifications forbidden
The system may only be operated in its original condition or with a structural
modification that has been carried out by authorised Baumer hhs personnel. Any
unauthorised structural modification of the system is forbidden! This especially
applies to electrical equipment and safety devices.
National laws and regulations

Make sure that you have a comprehensive knowledge of national laws,
requirements and regulations concerning accident prevention and environmental
protection. Comply with these laws, requirements and regulations! The
institutions for statutory accident insurance and prevention and the local
authorities will provide information on this.
Personal protective equipment

Personal protective equipment must be worn during all work on the machine. In
this regard, observe the information provided in the safety data sheets supplied
by the manufacturers of the operating and process materials, in this operating
manual and in the operating instructions of assembly units from other
manufacturers.
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Personnel qualifications
Baumer hhs distinguishes between personnel for various activities on the
machine, which require a different level of qualification.
Operating the machine:
The machine may only be operated by personnel that have been instructed by
Baumer hhs. Machine personnel must be familiar with the content of the
operating manual and be instructed regularly, at least annually, in safety-related
issues.
Electrical work:
Electrical work may only be carried out on the machine by a skilled and qualified
electrician.
Mechanical work:
Mechanical work (apart from set-up and adjustments) may only be carried out on
the machine by a skilled and qualified mechanic.
Software modifications:
Software modifications may only be carried out by Baumer hhs personnel or
skilled persons who have previously been instructed in handling by Baumer hhs.
Any additional software installed on the control system will result in termination of
the operating licence. This especially applies to software that enables internet
access, games or entertainment media.
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Improper use
Improper use of the system and the associated assembly units produced
by other manufacturers results in unforeseeable, uncontrollable, life-
threatening risks for operating personnel and/or serious damages!
Improper use basically consists of any use or handling that deviates from proper
use.
In this case, Baumer hhs refuse all liability and places sole responsibility on the
operating company.
Any manipulation of end switches on equipment, e.g. on safety devices, which
are provided for the purpose of personal safety, is deemed improper. This poses
an extremely high risk for machine operators. Any means of simulating that
protective equipment and safety devices are in place are forbidden.
Any modifications, additions or alterations to machines or assembly units
produced by other manufacturers, which have not been expressly approved
beforehand in writing by Baumer hhs, are also deemed improper.
The supplied software may not be modified or replaced with third-party
software. Furthermore, the electrical voltages may not be modified. Any
unauthorised modification to the software or the machine's electrical power
supply is also deemed improper.
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General operator duties

Train all personnel in handling the machine, related equipment and process
materials safely before commencing an activity on the machine. Document the
training sessions. This operating manual and the safety data sheets supplied by
the manufacturer of the equipment and process materials form the basis of the
training.
Responsibilities during assembly, commissioning, operation and repair works

must be clearly specified and adhered to.
Carry out regular (at least annual) refresher training in safely handling the
machine, related equipment and process materials regularly! Document the
training sessions!
Draw up operating instructions for safely handling the equipment and process
materials that are used on the machine.
Request safety data sheets for all equipment and process materials (cleaning
agents, adhesives, lubricants, etc.) Update the safety information regularly.
Keep the personal protective equipment, which is specified for the respective
activities in the operating manual and in the safety data sheets, available for your
employees.
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Life phases of the machine / operating modes

The safety requirements, the requirement for the level of qualification of
personnel, as well as operation, can vary depending on the life phase of the
machine. The life phases will be mentioned repeatedly in the following chapters.
Knowing the individual definitions is required for understanding the subsequent
chapters.
The following life phases are thereby distinguished:
• Transport, assembly and commissioning
• Set-up / configuration
This phase describes preparatory work for production.
A feature of this phase is that the machine does not continually transport the
substrate during set-up.
This phase requires qualified and trained machine personnel from the operating
company.
• Production
This phase describes product manufacturing.
A feature of this phase is that the machine continually transports the substrate
during production.
company.
• Maintenance / repairs
This phase describes all maintenance work on the assembly unit, such as
replacing components.
company.
• Disassembly / decommissioning
This phase describes the disassembly and decommissioning of the system. This
phase requires personnel who are familiar with proper disassembly and disposal.
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Safety requirements
General
Only qualified personnel may be assigned to the corresponding work.
Safety during transport, assembly and commissioning

• Make the operating manual available and easily accessible in close proximity
to the machine.
• The machine must be depressurised before material connections and air
connections are mounted.
• Only lift heavy parts using a crane or with assistance.
The machine must be installed in an easily accessible location.
The installation site must be designed to hold the entire weight of the machine.
It must be possible to safely load the machine with material.
The following applies to the electrical connection and cabling work:
DANGER!
Only carry out work when disconnected from the power supply!
Ensure that the machine cannot be turned back on unintentionally.
• Only qualified personnel may work on electrical installations.

• Before commissioning, compare the permissible mains voltage with the mains
input voltage.
• Protect the machine against short-circuit on site.
Take notice of the total current consumption in the "technical data".
• The protective earthing must comply with the applicable regulations.
The following applies to the operation and use of fittings:

• Only use replacement or additional fittings recommended by Baumer hhs.
Only original devices, such as valves, signalling devices and related
connection cables, produced by Baumer hhs may be used.
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♦ Pictograms
Some Baumer hhs products are provided with safety pictograms. The pictograms
indicate residual risks to the end user.
The pictograms must not be damaged or covered by machine elements.
Replace damaged or covered pictograms with an identical pictogram.
DANGER:
The user can sustain injuries if pictograms are covered or damaged. The
user cannot correctly assess the risk without the pictograms.
Safety during production
- Do not operate the machine without the intended coverings and safety
devices.
- Be careful with uncovered, moving and rotating parts.
HAZARD !
The system may not be operated
Near
- flammable materials
- volatile materials
- explosive materials
- explosive gases
Operating must be ceased immediately if

- there is an uncontrolled situation.
- a fault is identified in the electrics or cabling.
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Safety during maintenance, repairs
CAUTION!
Before any repair works, make sure that the system is disconnected from
the power supply and depressurised!
DISCONNECTED FROM THE POWER SUPPLY:

Disconnect the main current supply
Ensure that the machine cannot be turned back on unintentionally.
DEPRESSURISED:
Set the total pressure of the machine to 0!
- Ventilate the pressure tank and switch off the pump.
- Open the application valves to release any present residual pressure
- Open the ball valves on the material pressure regulator and distributor
CAUTION!
Make sure that the pressure has actually been removed. A dry coating
medium can close up the outlets. Check the pressure on the manometer
All manometers must display 0 bar.
Notice:
• Only use original replacement parts.
• Only lift heavy parts using a crane or with assistance.
• Only clean the machine using suitable cleaning agents.
Observe the manufacturer's data sheets.
• Regularly check the live cable and wires for:
o Insulation faults
o Breakages
Only carry out inspection or adjustment work if a second worker is present who
can provide immediate assistance in the event of an accident.
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Safety during disassembly and decommissioning
DANGER!
Pay particular attention to compliance with the safety regulations during
disassembly and decommissioning.
The correct suitable protective equipment must be worn.
Make sure that the machine is disconnected from the power supply before
disconnecting electrical connections.
Make sure that the machine is disconnected from the power supply before
disconnecting mechanical connections.
Only carry out disassembly or decommissioning work if a second worker is

present who can provide immediate assistance in the event of an accident.
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Personal Protective Equipment
Wear personal protective equipment! Cover all body areas that may get in
contact with glue:
- Protective clothing
- Protective gloves
- Tightly fitting safety glasses with face protection
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4. Description of the System
XTS²-Xcam PF AM
Stand-alone
10328260 XTS²-Xcam PF AM
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Stand-alone
4. Description of the System
Technical description
Functional Description of Xtend² Series
The fact that it is possible to manufacture various production pieces on one

machine is determined by the every day growing manufacturing rate and
flexibility. These factors, in their turn, make high demands to the complementary
devices, such as glue application systems and quality monitoring systems.
Malfunctions resulting from pressure or those happening when cutting, and
special functions, such as hologram gluing, as well as folding and gluing must be
monitored by the machine in any situation.
Xtend² devices – is a module-based embedded system, created for the glue
application process control, for the production quality control. It is a guarantee of
the successful manufacturing process.
Xtend² displays the real speed when machine works at high speeds. At the
moment when workpiece passes through the machine, it is scanned and,
according to the set parameters, detailed information is displayed.
Unhindered extraction of the defected workpieces via the ejector device
substantially affects manufacturing rates. Start and stop are the most critical
moments: at that time work-pieces can be pulled the wrong way and while the
machine is switched off glue accumulates, which, in its turn, leads to the wrong
glue application or to a situation when several workpieces are captured by the
machine at once
Controlling terminal is a multifunctional device with easy visual control.
Example of functional module block
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8. Quality Assurance
Technical description
Xtend² Folding machine
The machine is shown schematically on the main page. The settings necessary
for a job can be accessed from here.
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Stand-alone
Camera module function

The camera module takes over the control of cameras for the monitoring of
products. The camera module consists of the control module and at least one
camera with corresponding lighting.
The folding machine camera system serves for monitoring the mixing of products.
Two cameras (one from above, one from below) each check the compliance of
the product with a prior learned feature.
You can select between the following control tasks.
Code Reading of 1D & 2D codes
Mustererkennung Pattern recognition
Texterkennung Reading of text (yet not implemented)
Schimmelbogen Checking for the presence of printing
The software offers different evaluations of the image information, such as code
reading, blank sheet detection and pattern comparison.
After the start sensor (optical switch) has identified the blank, the distance
information received from the encoder is evaluated and, on reaching the position
entered in the model, the camera and lighting are activated.
The code reading function reads and monitors a code in the image. This can be a
barcode or a 2D code. The code type(s) to be read is/are recorded during
teaching and specified together with the code content for the monitoring.
The pattern recognition searches for a pattern in the image. It is then compared
with an image from a previous teach in run.
During text inspection, a text will be checked for presence and for concordance
with a taught reference text.
The blank sheet check examines the contrast in an image section in order to
determine whether or not the sheet has been printed.
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Technical data camera module
Power supply
- rated voltage .............................................. 24 V DC ± 10 %
- Power consumption ................................... 500 mA, including power
consumption of components
- Fuses......................................................... Safety device with flat connector 3
A, GIS 72581
Dimensions and weight
- Dimensions W x H x D ............................... 106,6 mm x 128,4 mm x 96,5 mm
(dimensions are given without
connectors)
- Weight ....................................................... 830 g
Ambient conditions
- Ambient temperature ................................. 0 ... + 40 °C
- Storage temperature .................................. - 20 ... + 60 °C
- Degree of Protection .................................. IP 20
Machine
- max. Machine speed .................................. 600 m / min
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Technical Data display XTS² VGA BG-15“
- type ........................................................... Touchscreen

- art.-no. ....................................................... 75010360
- screen........................................................ 15”
- power supply ............................................. 1N~ 90-126 / 184 - 253 V
- frequency ................................................... 50 / 60 Hz
- degree of protection ................................... IP 52
- allowed temperature .................................. 0 ... + 50° C
- allowed relative humidity ............................ 0 ... 90% at 35°C not condensed
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Transport and Assembly

Check system for completeness and damages.
Connections – ‘CODE & CAM’ glue monitoring module
SENSOR A, B
For connection of Scan300.
RS232
Connector for RS232 interface
START A – D
For connection of external light barriers. .
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ENCODER
Connector for the encoder. Length-dependent pulse from machine in stand-alone
mode of the monitor. When using the T&E tracking module nothing is connected
here; instead, the signal is made available internally..
STATUS
Connector for the status light (red yellow green blue)
LIGHT
Voltage supply for the camera
LIGHT CTRL
Connector for the flash controller (if present. Supplies the flash trigger signal to
the flash controller module)
CAM
Connectors for cameras (the I/Os of the cameras go via these, i.e. take picture,
product good / bad)
OPTION
Transfer of good/bad signals or machine stop signal to external controller (PLC,
machine etc.)
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Handling and Operation
♦ Home
This is the main page being used. From here, you can switch to view the
submenus of various monitoring functions, the glue pattern programming, and the
system settings.
1 Submenu Camera Surveillance: By clicking on the camera or the symbol for

the surveillance function once, you will open the submenu for camera
surveillance. Depending on the camera you select, you will automatically be
directed to channel 3 or 4..
2 Edit Water Order: Click once on the product shown in the first section to open
the submenu to program the water order. Depending on the section you select,
you will automatically be directed to the corresponding order header.
3 Edit Glue Pattern: Click on the product shown in the second section to open
the submenu for glue pattern programming. Depending on the section you select,
you will automatically be directed to the corresponding order header.
4 Ejector / Labeling: Click this button to open the settings menu for the ejector
or the labelling settings.
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Glueing Symbol Key

(gray) No glue pattern has been programmed.
(gray) A glue pattern has been programmed, but the valve is deactivated.
The valve will remain in dot mode.
(green) The glue pattern is programmed and the valve is active. The valve
will remain in dot mode.
(gray) A glue pattern has been programmed, but the valve is deactivated.
The valve will remain in dash mode.
(green) The glue pattern is programmed and the valve is active. The valve
will remain in dash mode.
Glue Surveillance Symbol Key

(gray) No glue pattern has been programmed.
(gray) A glue pattern has been programmed, but the sensor is deactivated.
(green) Sensor activated. The last product was correct.
(red) Sensor activated. The last product was faulty.

(blue) Sensor activated and in programming mode. The sensor is waiting for
a product.
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Camera Control Symbol Key
Camera Deactivated.
Camera set to Blind Print Page Control. The symbols represent the
current status: deactivated (gray), correct product (green), and faulty
product (red).
Camera set to Code Control. The symbols represent the current

status: deactivated (gray), correct product (green), and faulty
product (red).
Camera set to OCR Text Recognition. The symbols represent the

product (red).
Camera set to Pattern Recognition. The symbols represent the

product (red).
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General Symbols
Loading
The system is currently busy calculating. Entries can only be made

once the process has been completed.
Glueing deactivated
If the glueing process has been deactivated, this symbol will appear
over the products.
Xmelt Control
On this page you can remotely operate the Xmelt hot glue series
and control their status, provided that they are connected to the
system.
Exit Program
Closes the program and shuts the computer down.
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Operating Elements Xtend²
User rights
The system has several right levels. Distribute
passwords depending on the rights you want to
grant to a machine operator. In order to enter a
protected area click on the lock symbol.
Help
On each page you can call the corresponding
help adjusted to the size of the open page.
Glue line:
Clicking the glue line (or the free area of the
product) opens the menu for model editing
Gluing gun.
Clicking the gun (left) opens model editing
Glue sensor.
Clicking the glue sensor (left) opens model editing
LNT.
Clicking the LNT Symbols or the glue line within
the glue flap (top of page) opens the control of
contact gluing.
Code 1.
Clicking the Bar-Codes opens the job related
code settings
Code 2.
Clicking the Matrix-Codes opens the camera page
Code 3.
Clicking the EAN-Codes opens the job related
EAN code settings
Ejector.
Clicking the T&E Symbols opens the ejector
statistics
System settings (machine parameters)
Test mode (direct regulation, status scan)
Statistics (actual order estimation)
Release
(after machine stop or feeder stop, confirm with
this button to to start again the machine or the
feeder)
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Operation (switching between settings and

operation)
Settings (switching between settings and
operation)
Switch off all guns (all gun, that are active in
current model) tracking and ejection
Copy, COPY
leave, ESC
Confirm, DONE
Gluing data (Gun type, Sensor Distance)
Glue Pressure
Glue Detection
Code-Detection
System settings (Machine parameters)
Display (e.g. language, time, date, screen saver,

calibration)
Inputs and Outputs (e.g. parameters for external

plugs)
Encoder (e.g. resolution, assignment of guns)
Gun type (e.g. gun activation, Flap)
Ejector
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Create model
Delete
Save
Product length (value in mm)
Ignoring window (value in mm)
Dot space global (value in mm)
+/- Tolerance of glue detection (value in mm)
Number of correct products
Number of erroneous products
Number of ejected products
Number of distribution errors
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♦ Header Symbols
The currently selected job, the date, and the time are displayed on the header on
the home page. Additionally, you can read the speed of the machine and the
number of the good and faulty products.
1 Job Name: Displays the currently running pattern here. Click on the arrow
symbol in order to open Pattern Selection.
2 Date: Displays the current date here.
3 Time: Displays the current system time
4 Speed: Displays the current machine speed in meters per minute here.
5 Speed: Displays the current machine speed in units per hour here.
6 Pieces: The previously produced, good products will be displayed here.
7 Pieces: The number of faulty products will be displayed here.
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♦ Camera side operating elements

General operating elements on the camera side.
Activation or deactivation of the camera channels
Selection of the images to be displayed

All => all images are displayed
Off => the currently displayed image is frozen
Error => only erroneous images are displayed
Live => a live image is displayed (can be selected
only in setup mode, not during running production,
since no more monitoring then takes place)
With this button you can display the last 10 errors.
You can scroll through the errors using the adjacent
arrow. Monitoring continues in the background
Zoom in and out on the current camera image
Select the display elements for the monitoring task
Setting of the reading area. The specified dimension

corresponds to front edge of the product – centre of
the exposure window
Position compensation (yet not implemented)
Draw a new search area
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Teach the current monitoring task
Date / time: display of the date and time at the top left
of the screen
Counter: display of the number of products at the top
right of the screen
Frame: display of the search area
Result: display of the monitoring results (value, angle
etc.)
Graphic: graphical display of the monitoring results
Processing time: display of the evaluation speed
Light colours: can be activated if the text is not
readable due to the exposure image.
The product count in brackets and behind it a *
means that this was only a check for the purpose of
updating the display (e.g. display of the changed
search area). This check does not output a good/bad
signal and is not included in the statistics.
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Operating elements for the code check
Setting of the code type sought during teaching. (Auto:

EAN8 / EAN13 / Code 39 / Code 93 / Interleaved 2/5)
Learnt code type
Learnt code contents
Maximum permitted rotation of the code, based on the
learnt orientation
Search speed
This check box can be checked if the code contents

deviate, but the same type of code is always present.
Only the correlation of the type of code is checked, not
the code contents.
Use, for example, with sequential numbers.
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Operating elements for pattern recognition
Minimum correlation
Maximum permitted rotation of the code, based on the
learnt orientation
Size of the search area.
Search speed
Operating elements for the blank sheet check
Minimum permitted amount of filling of the printing,

based on the taught product.
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♦ Orientation in Menu
Chapter „Initial operation“ describes the settings, to be done only once for setup
or at redesign of the machine. Afterwards all settings can be found in
„Production“.
All settings, that can be seen on start screen close to the product, are saved as
model for this job only.
Production See Production

Ejection See Production
Statistics See Production
Model See Production
Test See Troubleshooting
Data Data / Code See Initial operation
Data / Installation Display See Initial operation
Input / Output See Initial operation
Encoder See Initial operation
Ejector See Initial operation
System data See Initial operation
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Initial Operation Controller
♦ Basic Software Settings

The Controller is prepared for several operating environments. Adopt the settings
before the first OPERATION to your machine configuration.
Before start of normal operation you should examine the following setup:
• Language (can)
see chapter troubleshooting
• Gun-Type (must)
Each gun has got its own electrical parameters. Choose from a variety of
guns. See GUN-TYPE.
ATTENTION !
Erroneous selection can damage or even destroy your application head.
• Encoder (must)
Enter encoder resolution: It’s the distance a product makes with each
encoder-puls. You can find out the resolution by trial.
• Start sensor allocation and distance (must)
To position the glue correct on your product, the controller needs to know the
distance from Start sensor to each application head. Measure the distance in
direction of transportation. Enter the measured value for each application
head in “Offset”.
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♦ Offset and Start sensor connection

Start-Sensors (Light-Barriers, Initiators) detect front edges in separate products
and printed marks in reel products. For separate products (Folding cartons,
Mailings) they are placed in direction of transportation before the cameras. The
distance to the camera (maximum one format) is given by the holder. The Offset
value is the distance between light of the sensor and the middle of the camera.
Assign each camera you want to use to 1 of the start sensors (Light barrier or
Initiator).
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Glue Pressure
Commissioning: camera module
♦ Setting the offset and assigning the light barriers

These settings are made once during the installation. This value does not need to
be changed as long as the positions of the light barriers and the camera are not
changed.
1 Sensor Type: Here, the installed camera or sensor types will be displayed on
the corresponding channel.
2 Light Barrier: Here, you can select the light barrier from which the camera or
sensor should be started.
3 Offset: Here, enter the distance between the light barrier and the camera's lens
middle or the sensor's control point.
4 Option: Reserved for specialized applications.
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♦ Camera image parameter settings

These settings must be made once during the installation. It may be necessary to
adjust the settings if the heights of the cameras are changed.
→ →
1 Camera Type: The connected camera type. The TXG03 with a resolution of
656 x 490 pixels is the standard resolution for the folding machine. The camera
type can be changed in the service menu.
2 Optional Configuration: Optional camera configurations can be uploaded for
special applications.
3 Enhancement: You can set up a factor to enhance the image here. The larger
the value, the brighter the image.
4 Exposure Time: You can set the exposure time in microseconds in this field. It
should be approx. 100 microseconds. A higher value increases the brightness of
the image but can blur the image if the pictures are taken at high speeds.
5 Image Display: Set the image display to Live Image in order to be able to set
the lens's aperture and focus. You can zoom the view in and out using the
buttons for the lens.
Off: No image is displayed.

Live: An image is constantly being displayed. All of the camera's control
functions have been temporarily deactivated!
Trigger: Normal operation. A picture will be taken when the light barrier signals
the presence of a product. An evaluation will follow.
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♦ Setting of aperture and focus
The objective of the camera
The objective of the camera consists

of two components, aperture and
focus.
At the aperture, the brightness can be
regulated, and the focus adjusts the
image sharpness. Both setting are
secured with fixing screws.
1 Fixing screw aperture

2 Fixing screw focus
3 Setting aperture
4 Setting focus
Focusing the camera
To change the focus, rotate the setting ring to focus. Proceed as follows:
Step 1: Remove the cover of the camera. The objective should now be
accessible.
Step 2: Activate the live image Display at one of the adjusting pages of the
Camerafunctions.
Step 3: Carefully loosen the focus locking screw.
Step 4: Turn the focusing ring until the camera image is sharp. Carefully tighten
the focus locking screw.
Step 5: Deactivate the live image.
Step 6: Attach the cover and protection glass of the camera again.
Adjusting the brightness
To change the brightness, rotate the setting ring to aperture. Proceed as follows:
Step 1: Remove the cover of the camera. The objective should now be
accessible.
Step 2: Activate the live image Display at one of the adjusting pages of the
Camerafunctions.
Step 3: Carefully loosen the aperture locking screw.
Step 4: Turn the aperture ring until the brightness is obtained. Carefully tighten
the aperture locking screw.
Step 5: Deactivate the live image.
Step 6: Attach the cover and protection glass of the camera again.
Alternatively the image brightness can be adjusted via the exposure time at page
Data / Installation / Camera.
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System Settings
♦ Language and Time settings
→
Data entered here will not influence machine results.
Date and time. Touch the respective field and enter desired time. Then confirm
with DONE or leave with ESC.
LANGUAGE
Press the flag of your desired language. Confirm with DONE. Now the whole
application will switch to your selected language.
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♦ Inputs and Outputs

On this page, you can adjust settings to influence the actions of the control's
inputs and outputs. Additionally, settings possibilities exist here for the number of
allowable sequence errors before an insert stop is triggered.
1 Start: Here, you can logically link start signals together.
Disconnected: The controller will individually evaluate the sensors entered into
the offset / start.
And: Both signals are simultaneously necessary in order to start glueing.
Or: The presence of only one of the two signals is necessary in order to trigger
glueing.
2 Reset In: Select which action is triggered when "Reset In" is active.
Block Glueing: The glueing will be interrupted for the duration of the active
signal.
Head Control: To control a pneumatic traversing unit. Not used for the camera
system folding machine.
Discard Patterns: A product located in the offset of the glueing process will not
be glued on a rising edge during "Reset In".
Counter: The product counter will be reset.
3 Ready Out: Determine the condition at which the output "Ready Out" will be
activated.
Clean: If the system is turned on in test mode, "Ready Out" will be activated.
Valve: As soon as at least one valve is activated, the output will be turned on.
Level: Using the selection, the logic of the "Level In" input can be defined as a
closer or as an opener.
Counter: When the preset batch counter is reached, the output is active.
4 Level: Using the selection, the logic of the "Level In" input can be defined as a
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5 Reset: Using the selection, the logic of the "Reset" input can be defined as a
6 Ready: Using the selection, the logic of the "Ready" input can be defined as a
PLEASE NOTE: The output is not a potential-free contact but is a

connected control voltage +24V
7 Slider Closure: Determine when the "Flap" outputs will be activated here.
Off: The outputs are never connected.

Start: The outputs will be active when a start signal is received on any glueing
CPU channel while the machine is running.
Speed: The outputs will only be active when the machine speed exceeds "V-
min".
Start+Speed: The outputs will be active when the machine speed exceeds "V-
min" and a start signal is received on any of the glueing CPU channels.
8 Delay: The "Flap" outputs will still remain active for the set time, even if the
start-up condition selected under 7 is no longer being met.
9 Automatic Cleaning: Assuming the existence of a swivel- and cleaning
apparatus, you can clean the valves at predetermined intervals.
9a Interval: Enter the desired cleaning interval in minutes here.

9b Duration: Determine the active duration of the cleaning apparatus here.
9c Distance: The distance from the depositor to the cleaning apparatus. This
distance is required to ensure that the machine is empty of products when the
cleaning is scheduled to begin..
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10 Time Stop: This function is to prevent products with dried glue to remain in
the production. The time to be set thus depends on the time the glue takes to dry.
This function stops the feeder of the machine, when the machine stops longer
than set as time stop. When the machine starts again, all products in between
glue sensor and light barrier 1 will be ejected.
Products are considered faulty as soon as they take more time to pass the
defined distance than the set time value (e.g. due to a machine stop). These
products are excluded from sequential error registration.
A time stop is only activated if some products will not pass the defined distance in
the set time AND if products were considered correct on a defined distance
before this. These products will be ejected to prevent them from remaining in the
production line.
An automatic release will activate, if the following criteria are met:
• Time stop is active,
• There are no additional error messages,
• Modul is in operation mode (not in setu- or programming mode),
• Automatic release is set enabled (factory setting: YES)
• Ejection control registered the time stop:
Device without Compact / Xtend eject control:
• const. delay 5 sec.
Device with Compact / Xtend eject control:
• Time stop iInfo was requested via SKG-Bus,
• Min. delay: 2 sec.,
• Max. delay: unlimited (if no request is made)
If these criteria are not met, the release can be done manually.
11 Sequence Errors: Here, determine how many errors in a row can trigger an
insert stop. If this number is exceeded, the contact "Insert Stop" will b switched.
These settings are valid for all error causes except for errors from the code
reader.
12 CR Sequence Errors: Here, you can determine how many errors in a row in
the code reader can trigger an insert stop. If this number is exceeded, the contact
"Insert Stop" will b switched.
13 Start Delay Counter: Here, you can specify a quantity of items by which the
activation of the glue surveillance with ULT sensors will be delayed. While the
glueing process is taking place, the glue surveillance will only become active
after exceeding the number of products specified here. This function will be used
in endless applications with machine stoppage, which may typically have initial
difficulties.
14 Delta V: Specify a number of items here by which the activation of the glue
surveillance with ULT sensors will be delayed. While the glueing starts when the
minimum speed reaches V-min, the glue surveillance will only become active
after exceeding the V-min plus the value entered here. This function will be used
in endless applications with machine stoppage, which may typically have initial
difficulties.
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♦ Encoder
An encoder detects the speed of the machine. The encoder parameters allow
you to adapt the machine to the resolution of the machine encoders.
INFORMATION :
The accuracy of this setting influences directly your gluing accuracy.
The encoder for detection of the glue position should preferably be coupled to the
machine in such a way that a sufficient number of pulses is generated for each
forward movement. Different encoder resolutions can be taken into account, by
making appropriate entries in the machine data. The controller translates the
pulses in such a way, that you can enter values in length units.
For encoders from Baumer hhs:

Encoder 1 readings (real-time clock that registers machine speed in the section
of folding and gluing) are given in the following units of measurement:
pulses/mm.
Encoder-Type Recommended setting

hhs-508-AB friction wheel 0,5 mm/p
hhs-254-AB friction wheel 1,0 mm/p
hhs-100-AB toothed wheel 1,0 mm/p.
INFORMATION:
At max. machine speeds the encoder frequency may not exceed 20 kHz!
With higher frequencies the gluing accuracy will get lost.
For encoders from other manufacturers

- Find a distance value on display.
- Measure the same distance on your product.
- Divide the value "Measured-Distance" by "Set-Distance" and multiply with
your so far entered encoder resolution.
- Enter the result as new encoder value.
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Encoder Connection
This menu defines whether the corresponding modules (gluing, control, pulling
and ejection) have an encoder (internal) or have an access to the encoder of the
adjacent module (external).
In order to assign some guns to the 2nd encoder, in field 1 indicate the channels
that shall operate with the encoder 1. If you choose the gun № 5, the guns 1-5
operate with ENC1, and the guns 6-8 (with a 8-channel device) with ENC2. If a
device has more than 8 channels all the other guns are assigned to ENC2.
When you define a second encoder here, you will find an additional field for an
ignore window on the gluing page. It is used when you operate a right angle
machine resulting in different product length and spacing.
Speed
The field „Actual Speed“ contains actual speed depending on the corresponding
value of the encoder.
Interpretation
Upon activating the parameter „Interpretation left/right “ the function of rotation
direction detection operates „clearly“, i.e. encoder signals are permitted only in a
certain direction. If the rotation is performed in the opposite direction, the encoder
signals are suppressed. Active direction is defined by the parameter „Right
Direction“(„activated“for the right rotation and „deactivated“for the left rotation).
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→ →
Connection Selection of the encoder source.

External is standard with the CR module
Resolution Setting for the encoder resolution.

Dependent on the encoder
Right direction Activation of the direction of rotation correction.

Dependent on the installation situation
With the CR module, encoders must be used that supply the A & B signal.
If the settings are correct, the field ‘Act. speed’ displays the actual machine
speed. Changes are only accepted when the green button is pressed. You can
return to the window again to check.
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♦ Connections
On this page, you can make adjustments to the connections between the
operating system and the machine and you can determine connection settings for
possible Xmelts.
1 Machine Connections: Select the protocol type appropriate for your machine.
Define the interface on the computer by selecting the COM connection and the
rate of transmission used.
2 Xmelt Connection: At this point, you can determine whether an Xmelt has
been connected. If you are working with Xmelt, you can determine here which
interfaces are being used and you can determine how many devices are
available.
3 Glueing Communication: In this side area, you can determine which interface
should be used to communicate with the glueing process. Depending on the
structure of your system, you must choose between the "CAN Interface" and
"COM-X Communication Connection", in which X represents the utilised COM
connection to the PC.
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♦ Setting up Labelling
The labelling equipment can be used for spray labelling as well as for ejector
control in order to eject faulty products. The parameters necessary to do so will
be set up here.
1 Ejector / Labelling Type: The actions of the ejector control when the machine
is stationary can be determined here.
Valve: The control will be suppressed as long as the machine is at a standstill.

These settings must be used for the spray valves so that these do not spray the
product when idling.
Mechanics: The ejector control will remain active even when the machine is at a
standstill. These actions are required for an ejector so that it does not turn off
when at a standstill and traps products. The ejector will close after every faulty
product.
Mechanics (with stops): Just as for the "Mechanics" setting, the ejector will
remain open even if the machine is at a standstill. Additionally, in case of a faulty
product, the ejector will remain open until the next good product has passed the
ejection point.
2 Compensation Time: Enter the ejector's compensation time here in order to
compensate for the mechanical inertia. It takes a certain amount of time from
sending the command until actually reaching the opened position so that the
product can be ejected properly, even at high speeds.
3 Sequence Errors: Here, determine how many errors in a row can trigger an
insert stop. If this number is exceeded, the contact "Insert Stop" will be switched.
4 Activate / Deactivate: Check the box to activate or deactivate the ejector or
the spray valve.
5 Labelling Position: Determine the length and positions of the spray valves
here. When using a mechanical ejector, set the values "from 0 mm" "to 0 mm". In
this case, the ejector will be driven over the entire product's length which is
automatically measured by the system for each product.
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6 Ejection Cross-Check: In order to ensure that ejection occurs correctly,

ejection cross-check can be enabled. In order to do so, a light barrier must be
selected here. If the control wants to eject a faulty product but no product
subsequently passes under the corresponding ejection cross-check light barrier,
the feeder will stop due to an ejection error. The distance required to do so will be
measured from the ejection point to the corresponding light barrier and must be
entered into the field.
7 Synchronisation Light Barrier: Activate a synchronisation light barrier here. If
you would like to use this, the graphic display will change and you will need to
enter another distance. You will find an explanation for using a synchronisation
light barrier at the bottom of this page.
8 Distance Ejector: Here, enter the distance from camera to the ejector. In case
you have more than 1 activated cameras, enter the shortest distance. In doing
so, you have determined the ejection time. If you turn off one of the two cameras,
it may be necessary to change this distance, as these may lie at different
distances from the ejection point.
Using a Synchronisation Light Barrier
1 Synchronisation Light Barrier: If you have selected a synchronisation light

barrier, you only need to enter the distance from the synchronisation light barrier
to the ejector 1a. The distance from the camera to the synchronisation light
barrier 1b will be automatically measured during a programming drive. The impact
of potential slippage of the product will be significantly reduced by utilising the
synchronisation light barrier. Ejections will be controlled much more accurately.
If you turn off one of the cameras or change the shooting position, you will only
need to run one programming drive. The distance from the camera to the
synchronisation light barrier 1b will be automatically measured.
PLEASE NOTE:
Please be sure to observe the minimal required distance between the
camera and ejector.
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♦ Minimum Distance between Camera and Ejector

When positioning the camera, a specific minimum distance from the ejector may
not be undercut.
[1] Reading Area Position: The
image capture position, measured
4 distance components must be added for from the product's beginning
this minimal distance between camera and
ejector. [2] Evaluation Time: The time the
surveillance requires to evaluate.
[3] Minimum Delay Distance: A

fixed value of 35mm used for
internal calculations.
[4] Ejector Compensation: The

time the ejector needs to
mechanically open.
[1] Reading Area Position: 200mm
[2] Evaluation Time: 100ms
[3] Minimum Delay Distance: 35mm
[4] Ejector Compensation: 80ms
Calculation Example: 120m/min will be accepted as the

speed, which represents 2mm of
product feed per millisecond. The
following distances can be
calculated from the times:
[2] Evaluation Distance: 200mm

(100ms at 120m/min)
[4] Compensation Distance: 160mm
(80ms at 120m/min)
If all distances are added together,

the result is the minimum distance
between the camera and ejector.
200mm + 200mm + 35mm +
160mm = 595mm
At these reading area, evaluation time, and ejector compensation settings, the
camera must also be at least 595mm away from the ejector! If this distance has
been set to less, a warning message will be displayed. Increase the distance
between the camera and ejector or optimize the control task by managing the
product close to the leading edge, or shut off control functions that raise the
calculation time.
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♦ Service
You can set up basic system functions and activate available modules on this
page.
1 Module Activation: You can activate the modules installed in this system using
these buttons. Adjustments should be made by Baumer-hhs service personnel.
2 Camera Type: The connected camera type for channels 3 and 4 will be
selected at this location. The TXG03 is the standard for folding machine systems,
a matrix camera with a resolution of 656 x 490 pixels.
2b Option: Determines the actions of the Code & Cam modules The CR-CAM
setting is standard for folding machine systems.
3 Pump: Select the pump that will connect to the system here. You have the
following options:
KPE9 + PMPRE: Electric piston pump 09:01 AM with electronically controlled

pneumatic material pressure regulator.
KPE9 + MPR: Electric piston pump 09:01 AM with manual material pressure
regulator
PPE6: Electric piston pump 06:01 AM
PPE2: Electric piston pump 02:01 AM
IP Converter: IP converter, pressure regulator proportional to the current.
4 Pressure Output 2: Activate the second pressure output here and determine its
source.
Off: The second pressure output is deactivated.

0-20mA Enc1: The speed for the second pressure regulator will be taken over by
Encoder 1.
0-20mA Enc2: The speed for the second pressure regulator will be taken over by
Encoder 2.
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5 Number of Valves: Determine the number of valves in the system here and
determine the sections in which these valves are located. The number before the
hyphen specifies the valves in section 1; the second number specifies the valves
in the second section of the machine.
6 Stop Model: When you stop the machine during gluing, you can define here,
what the machine should do after restart. If a product stops under the gun:
"YES": The controller will ignore the partly done model.
"NO": The controller will save the partly glued model.
The entry will not be used until restart of the machine.
Info:
If you resume gluing after restarting, you run the risk that glue on the first
part will no longer stick.
7 Start v=0: You can define here what the controller does when detecting a start
signal at downtime.
"YES": The controller finishes the partly done model after restart of the machine.
"NO": The controller ignores start signals detected at down time.
Info:
Baumer hhs recommends the setting ‘no’. This way you avoid fingers or
cloths under the start sensor being detected as product at restart. The first
product would then be incorrectly glued.
8 Rinse Mode: Determine how the valves should act here when the rinse button
on the valve is pressed. You can choose between constant rinsing and a dot
frequency.
9 Order Type: Adjust the appearance of the home page to the machine type.
Folding Machine II is schematically forming one angle machine.
10 Measuring Unit Encoder: Convert the lengths entered from mm to inches
here.
11 Reset Counter to Zero When Programming: If this function is enabled, all
counters will automatically be reset to zero during programming drives.
12 No Setup Errors: If this function in enabled, no faulty products were detected
in the setup mode.
13 Reset Statistics: If this function is enabled, a button will be displayed on the
statistics page that enable the counter to be manually reset.
14 Snippet Filter: In order to avoid undesirable production stop the products will
be ignored if their length doesn’t coincide with the length you have defined here.
Maximum value is 20 mm, typical 15mm.
15 Hole Filter: Interrupting the start light barrier signal will be ignored up to this
length, which could otherwise restart the pattern processing. As long as a gap in
the product does not exceed this length, the glueing process will interpret the gap
as a continuous product. Value must be lower than in “fragment filter” (default:
5mm).
16 Standby: If this function is enabled, the glueing function will be in standby
when the program is started up. If the box has not been checked, the glueing
function will immediately be activated when the program is started up.
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User Rights
→ →
Info:
These entries apply for any job, even after turning off and on.
You can set the various user rights in the User Level menu. You must be logged
in with user level 4 in order to assign rights and to change passwords.
Display user level 1 to 4
User may not edit this item
User may edit this item.

A check mark in level 1 means that levels 2 … 4
have this right, too. You can only tick one box in
each row.
Code / Cam Rights to adapt or change camera monitoring tasks
Model Input Rights to change and edit the model data
Einr./ Progr. Rights to switch between operating and setup modes
and to perform a teach-run
Data Rights to set offset, ejector and light barrier
assignments
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Data / Installation Rights to change picture parameters and installation

data.
The device reverts to user level 0 (without password)
Timer when this time expires without any input.
The system allows the assignment of certain rights to users. You can decide and
set the access rights for 5 groups of machine operators. The left column is the
unprotected access for everyone (no code).
You will be informed of the password separately.
Info:
The system reverts to level 0 if no entries are made in the settings for a
while (timer in minutes adjustable). If a wrong password is entered the
device will revert immediately to level 0.
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♦ Example for Pattern Search

You can search for specific or any desired patterns in the database using this
function.
All jobs are displayed.
The job "Xcam" will be displayed.
All jobs containing the "Xcam" description will be displayed.
All jobs with "Xcam" at the end of their names will be displayed.
All jobs with "Xcam" at the beginning of their names will be

displayed.
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♦ Camera – Code Inspection

The code inspection inspects 1D or 2D codes according to specific criteria.
1 Activation / Deactivation: Activate or deactivate the individual camera

channels here.
2 Code: Currently selected control function for this camera channel.
3 Reading Area: Position of image recording on the product, measured from the
beginning of the product.
4 Search Area: Using this button, you can draw a search area within the image
in which the inspection task will be carried out.
5 Teaching In: This button triggers the teaching-in process. The search area will
be inspected with the selected parameters and a found code will be saved as a
reference. If the process fails, a red X will appear next to the button and the
process will have to be repeated with corrected settings.
6 Code Type Selection: Selecting the code types to be taught in. You can also
select the Auto function in order to recognise the code type automatically. This
function does not support the recognition of pharmacodes, as the reading
orientation must be given for this code. In order to automatically recognise
matrix- and other 2D codes, select Auto 2D.
Sample images of the most common types of code can be viewed using the [..]
button.
7 Recognised Code Type: Type of code stored as reference (set when
teaching).
8 Code Content: Content stored as reference code (set when teaching).
9 Maximum Distortion: Enter the maximum distortion measured from the
reference product here.
10 Only Code Type: If this function is enabled, it will only check whether a code
matching the taught code type is present in the search area; the content of the
code does not matter.
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11 Degree of Quality: Enter a minimum degree of quality for the code here.
During activated quality control, the codes will be verified during reading
according to ISO 15416 and evaluated according to criteria such as defects and
readability. This function is not available for all code types. Attention: This
function will increase the evaluation time. More information about the Degree
of Quality and Code Verification
12 Bar Control: When this feature is enabled, in addition to code reading, the
number of bars in the code will be counted and compared to the reference.
Additionally, this function checks the code bars for holes occurring through faulty
printing. Attention: This function will increase the evaluation time. Further
information: Examples of Bar Control
Point Distance (only data matrix code): Gives the distance between the points of
a data matrix code for specific printing techniques. This function is not necessary
for a standard data matrix code.
13 Display Options: Adjust the image display here. Find more information at
Explaining the Image Display Functions
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♦ Setting Up Code Inspection

1D or 2D codes can be inspected using the code control.
Search for a desired inspection area and measure the distance between
the product front edge and the middle of the control area (see image
1. Step below). Enter the measured distance into the "Reading Area" field on the
interface (section 3 under Camera - Code Control) and accept your entry
using the yellow button at the bottom left of the screen.
Arrow: Distance from

the beginning of the
product to the reading
area.
Frame: Code to be
inspected.
Now you can take a picture of the product. If the desired image area of
the product was not recorded by the camera, reposition the camera. To
2. Step do so, stop a product under the camera and switch the camera to Live
Mode using Image Display. Change the camera position so that you can
see the desired area. Then reset the display back to All.
If the desired image section can be seen on the next picture, you can
select the Code Control control task and adjust the search area. You can
3. Step
draw a new search area and move, reduce, or enlarge it. If the search
area is at the desired location, more settings must be adjusted.
Select the code type to be inspected from the list and enter a rotation
angle tolerance that does not exceed the code (sections 6 and 9 on the
Camera - Code Control page).
4. Step
After adjusting these settings, the code can be taught using the Teaching
In button as a reference. The recognised code type and its contents will
then be displayed on the interface (sections 7 and 8 in Camera - Code
Control). A yellow frame will appear around the code.
Afterwards, you will be able to set up the second camera and other
components such as ejectors, glueing, or other control functions. If these
have been set up or will not be needed, you must perform one final
5. Step
programming drive In order to do so, press the blue branch, which you
will find in the Setup mode in the lower button bar on the screen. A
message will appear.
Confirm the message using the green button. The upper status bar on
the interface will turn blue; the blue light for the signal lamp will also light
6. Step
up to show that the system is in programming mode. Only let one
product run through the machine.
The system will directly change into the production mode if the teaching
drive was successful. The green lamp will light up and the upper status
7. Step
bar on the interface will change to green. The system is now production-
ready.
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♦ Typical Errors during Code Inspection

During code inspection, observe the following points:
The code may not be covered by machine

components. The camera must be able to read the
complete code.
In order to be able to read the code, an area around

the code must be free. This area is called the "rest
zone". The rest zone is necessary for the code reading
to recognise that the code has ended at this point. The
rest zone may also not be covered by machine
components!
The image acquisition may not be too dark. There must

be sufficient contrast between the code and the
background.
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♦ Short instructions: code reading
Press the ‘Code’ button
Select what is to be read
The camera image is grey Set the code

before the first product
Let a product pass through.

Set the system to ‘Setup’
The camera image appears.
Measure the distance from the Activate the window for the marking of the
front edge of the product to the code.
start of the code Open the blue framed window over the
code with your finger on the screen.
Enter the value here
If the code is marked with the blue

window, confirm your entry.
Confirm your entry
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♦ Recommendations on the code creation

The Code Reader serves to read marketable code systems in the machine. In
this chapter the recommendations are given for the needs of the users who work
with this mechanism for the first time. They have a possibility to create an optimal
code for the system.
The single-track bar code consists of a sequence of bars printed wide and
narrow. Their combinations are organized in the binary system. From the number
of code bars the number of possible combinations can be calculated::
6
6 Codebar 2 = 64 Combinations
7
8
9
10
11
12
When creating print masters, the number of combinations required should be

estimated in advance, depending on the production variety.
Usually, 6 ... 12 bars satisfy the needs.
This codes match the requirements for quality control for high speed production
because they allow checking colour and printing quality at production speed
including longitudinal and lateral registration check - the code checking is not
limited to retrieving a number from the print as a simple UPC/EAN scanner would
do. Only the bars, but not the spaces carry information, which simplifies handling.
♦ Code Structure
One of the code samples with 8 bars can be used (256 possible combinations).
They can be extracted from the medium.
Code reading device allows selecting the following code types:
• Standard-code (colour analysis is possible)
• Pharma-code (colour analysis is impossible)
• Sample code (colour analysis is possible).
Info:
The selected code type must correspond with the printed code! Otherwise
mixing of code types can happen – unknown code error! Carefully check
whether the settings for each glue application project are set correctly!
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♦ Code bars and gaps width
Standard-Code
Standard code is known also as code 1-2-3, EMS code or wide pharma-code
(wide space pharma code). To carry out the measurements it is necessary to
adhere to the following recommendations:
x = Bars heightBars
standard height is:5 mm
Code structure corresponds to the principle 1-2-3:

• 1 mm narrow bars
• 2 mm gaps
• 3 mm wide bars.
The code that is created according to these recommendations is measured if in

the code reading device code type Standard is set.
This code is first of all recommended to be used in case of high machine speeds
and at the time of colour control.
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Pharma-Code
As an alternative Pharma-code can be used, which is also known as code 0-1-2.
It has the following parameters:
x = Bars heightBars
standard height is: 5 mm
This code structure doesn’t have any fundamental differences from the Standard-
code, however its parameters, namely, its bars width is almost half the Standard-
code bars
• narrow bars: 0,5 mm
• gaps: 1,0 mm
• wide bars: 1,5 mm
Code created according to these recommendations is measured if in the code

reading device Pharma-code is set.
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♦ Bars height
Bars height should be equal to 5 mm. The bigger height is a factor that leads to
increase in printing tolerance sensitivity, as well as to increase in machine
tolerance sensitivity.
In case of fine adjustments to the machine the height decrease to 3 mm
guarantees errors identification (starting from 1,5 mm) at the time of lateral
stamping-out even without the lateral registration triangle.
♦ Colors
While working with Standard-code colour identification is carried out at the wide
bars, therefore only wide bars in coloured code should be made coloured. For
narrow bars black colour should be used or any other contrasting colour.
While working with Pharma -code colour identification is impossible.
To achieve the best code identification results when using code reading device,
pay attention to the following recommendations.
• Narrow bars must be black.
• Wide bars can be coloured.
When using black, as well as other paint, it is recommended to apply standard
printing paint. That is, as a rule, when printing is carried out using intensive
paint, such colours as yellow, blue, purple and black should be applied. When
using mixed paint colour identification function is used with poor efficiency.
• Bitmap colours cause inhomogeneous colours, which may lead to inaccurate
measurements of colour and code.
♦ Registration triangle
In most cases it is enough to conduct lateral registration control, which is carried
out due to the code bars height analysis. If it is necessary to measure lateral
registration tolerance sensitivity, then the lateral registration triangle that is
located after code should be used.
This triangle must be located after the last code bar. Its angle must be 45° with
respect to the end of a workpiece in the direction of movement (see picture).
Info:
The horizontal displacement of a code area may be caused by some
displacements of a workpiece passing through the machine, as well as by
the marking printed on a workpiece with displacements.
The result of the completed lateral registration measurements is the thorough
adjustment of the machine which is determined by the well-tuned operation of the
folder and feeder functions.
Reading range
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♦ Position on a product
To position code on a product pay attention to the following recommendations for
the usage of the folder device of hhs firm together with CT 10 sensor. These
instructions are unnecessary when reading is carried out on a surface, and when
folder device of another manufacturer is used the values are slightly different.
When glue flap width is equal to 25 mm in order to have standard adjustments for
the code reading device, code must be located in the position that is shown in a
picture:
Bars height
x(standard: 5 mm)
Distance to the line Glue flap width up

of big:min. 7 mm to 25 mm
Code field position is defined with the help of the distance from the code medium
bar to the line of big – it must be 7 mm.
When products have greater width the distance to the end of product should not
exceed 40 mm, that is, code must be displaced in the direction of the line of big,
and the measuring head must be installed accordingly in the folder device.
♦ Code Creation Software

When it is possible codes should be created in the printing mode. Any graphical
program can be used for codes creation due to the simplicity of their structure.
Specialists in code development have improved applications, which are used for
the creation of different types of code. Firms stated below offer software for code
creation. These references are purely informative, that is we do not insist on their
direct use, because these products have not yet passed the testing stage.
Besides, customer should decide whether these products meet his requirements.
Demonstration programs and additional information can be received using the
following links:
Agamik bar codes and colour utilities: www.agamik.co.uk
SNX Bar Code Pro: www.snx.com
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♦ Degree of Quality and Code Verification
♦ General
Using the quality control function, barcodes will be verified when reading
according to ISO 15416. Note that the result for the code verification is strongly
dependent on the camera image settings. Sharpness and brightness must be
selected carefully in order to achieve an appropriate evaluation.
INFO: This camera function is not an approved testing device; it merely

gives a noncommittal statement about the quality!
Different degrees can be selected in code verification. If "No Quality Check" has
been selected, the verification is deactivated and will not be carried out. The
"Degree F - bad" selection applies to any code that can be read. Therefore, this
setting for a product can never be evaluated as faulty because of a too-low
degree of quality. In this case, the displays only serves to inform.
♦ Classification Table
Class Rmin Symbol ContrastECminModulationDefects Decodability

A = 4 ≤ 0.5 Rmax ≥ 70% ≥ 15% ≥ 0.70 ≤ 0.15 ≥ 0.62
B=3 ≥ 55% ≥ 0.60 ≤ 0.20 ≥ 0.50
C=2 ≥ 40% ≥ 0.50 ≤ 0.25 ≥ 0.37
D=1 ≥ 20% ≥ 0.40 ≤ 0.30 ≥ 0.25
F = 0 > 0.5 Rmax < 20% < 15% < 0.40 > 0.30 < 0.25
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Classification Table Explanation
Total code evaluation. A or 4 represents the best possible quality;

Class:
F or 0 represents the worst possible quality.
Rmin is the minimum reflexion value that is also used to
Rmin
determine the symbol contrast.
Symbol Symbol contrast is a measure of the maximum contrast difference
Contrast in a bar code symbol.
Edge Edge contrast is a measure of the minimum contrast difference in
Contrast: a bar code symbol.
Modulation is a measure of the uniformity of a bar code symbol
Modulation
calculated from the edge contrast and the symbol contrast.
The significance of the defects is calculated from white spots in
Defects
bars and from dark spots in the gaps and the light fields.
Decodability is a measure for the probability of initial reading
Decodability which is calculated on the basis of the reference decoder
algorithm.
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♦ Bar Control Examples

A pharmacode taught as a reference with 8 bars is an example of an error-free
product.
Correct: 8 bars, 0 holes
This product is correct, as it has the correct

number of bars and displays no breaks in the
code.
A code bar was printed incorrectly and was

broken into two parts. The product is faulty,
as 9 bars were counted.
The point between the code bars has been

recognized as an additional object and the
product has been evaluated as faulty, as it
displays 9 bars.
Because of a print error, two bars were

counted as one. The product is faulty, as only
7 individual bars were recognized.
Correct: 1 bar, 0 holes
The line connects all bars to one single

object. The product is faulty.
Correct: 8 bars 1 hole
Because of faulty pressure, an inclusion was

created in the code bar. The bar number may
be correct, but a hole was identified. The
product is faulty.
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This product is correct, as it has the correct

number of bars and displays no breaks in the
code. The print error that occurred here does
not change the bar number.
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♦ Camera – Pattern Recognition

Pattern comparison checks a product for the presence of a taught pattern and the
pattern's concordance.

channels here.
2 Pattern Recognition: Selected control function for this camera channel.
beginning of the product..
4 Search Area Using this button, draw a search area on the image in which the
print intended for the control task is located.
5 Teaching In: This button triggers the teach-in process. The content of the
search area will be taught-in as a reference pattern; the search area will
automatically position itself around the taught pattern inside the set distance.
6 Concordance: Enter the minimum concordance percentage to the taught-in
reference pattern here. Patterns whose concordance is less than this threshold
will be evaluated as faulty.
7 Maximum Distortion: Enter the maximum distortion measured from the
reference product here.
8 Maximum Displacement: Determine the size of the search area around the
original position of the reference pattern here, i.e. the number of pixels by which
the read pattern can differ from the reference position.
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♦ Setting Up Pattern Control

During pattern matching, a taught pattern will be inspected for presence and
concordance.
Search for a desired inspection area and measure the distance between
the product front edge and the middle of the control area (see image
1. Step below). Enter the measured distance into the Reading Area field on the
interface (section 3 under Camera - Pattern Recognition) and accept
your entry using the yellow button at the bottom left of the screen.
Frame: Area with
a pattern to be
inspected.
Arrow: Distance
from the
beginning of the
product to the
reading area.
the product was not recorded by the camera, reposition the camera. To
2. Step do so, stop a product under the camera and switch the camera to Live
Mode using Image Display. Change the camera position so that you can
see the desired area. Then reset the display back to All.
If the desired image section can be seen on the next
picture, you can select the Pattern Recognition control
task and adjust the search area. You can draw a new
search area and move, reduce, or enlarge it. During
3. Step
pattern recognition, the search area must be closely
drawn around the logo to be identified. If the search
area is at the desired location, more settings must be
adjusted.
Enter the minimal concordance and the maximum turning angle and
possible shift in pixels (sections 6 to 8 under Camera - Pattern
Recognition). After adjusting these settings, the pattern can be taught
4. Step
using the Teaching In button. A yellow frame will appear around the
pattern and the search area will be displayed in green. The size of the
search area can be changed by permissibly shifting the pixels.
have been set up or will not be needed, you must perform one final
5. Step
programming drive. In order to do so, press the blue branch, which you
will find in theSetup mode in the lower button bar on the screen A
message will appear.
6. Step
up to show that the system is in programming mode. Only let one product
run through the machine.
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7. Step
ready.
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♦ Typical pattern recognition errors:

Monitored pattern has been selected too
large. This can lead to long evaluation
times.
Select only one line (6. Inne informacje).
A feature similar to the monitored feature

occurs inside the search area.
Specify a different search criterion.
taught
77% correlation found
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♦ Camera – Blind Print Page Control

The blind print page control inspects a product for the presence of a printed
image.

channels here.
2 Blind Print Page: Selected control function for this camera channel.
5 Teaching In: This button will trigger a teaching-in process. The fill level in the
search area will be taught as a reference.
6 Filling: Enter the minimal fill level in percent here, measured on the printed
image of the taught reference product. Should the fill level of a controlled product
undercut this value, it will be evaluated as faulty.
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♦ Setting Up the Blind Print Page Control

The blind print page control inspects a product for the presence of a printed
image.
Search for a desired inspection area and measure the distance
between the product front edge and the middle of the control area (see
image below). Enter the measured distance into the Reading Area field
1. Step
on the interface (section 3 under Camera - Blind Print Page Control)
and accept your entry using the yellow button in the bottom button bar
on the screen.
Frame: Text to be
inspected.
Arrow: Distance
from the beginning of
the product to the
reading area.
the product was not recorded by the camera, reposition the camera.
2. Step To do so, stop a product under the camera and switch the camera to
Live Mode using Image Display. Change the camera position so that
you can see the desired area. Then reset the display back to All.
If the desired image section can be seen on the next picture, you can
3. Step select the Blind Print Page control task and adjust the search area.
You can draw a new search area and move, reduce, or enlarge it.
If the search area is at the desired position, the percentage of the
minimal fill level concordance must be given in the next step (standard
4. Step
value ~70%). The product will be taught as a reference using the green
button (sections 5 and 6 under Camera - Blind Print Page Control).
components such as ejectors, glueing, or other control functions. If
5. Step these have been set up or will not be needed, you must perform one
final programming drive. To do so, click the blue button, which you can
find in the Setup mode on the lower button. A message will appear.
the interface will turn blue; the blue light for the signal lamp will also
6. Step
light up to show that the system is in programming mode. Only let one
The system will directly change into the production mode if the
teaching drive was successful. The green lamp will light up and the
7. Step
upper status bar on the interface will change to green. The system is
now production-ready.
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♦ Typical Errors during Blind Print Page Control

During blind print page control, observe the following points:
The image may not be too light or too dark. A
clear contrast must be visible between the print
and the background.
In case the picture settings are too dark, you can

increase the exposure time or intensity in the
Data / Installation / Camera submenu. The Lens
Aperture can also be opened wider.
No machine parts should be visible in the search
area, as the gray value of these objects does not
change.
If an unprinted sheets with a slight gray value

has been recorded by the camera, parts
extending into the search area can distort the
result. It is possible that a sufficient filling level
was measured because of dark machine
components, which could also lead to non-
printed products to be evaluated as good
Move or reduce the search area until no machine

parts are visible.
The teaching process failed because not enough

filling is available in the search area. At least 3%
filling must be available. Search an area on the
product with more printed images or reduce the
search area.
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♦ Camera – Text Recognition (OCR)

During text inspection, a text will be checked for presence and for concordance
with a taught reference text.

channels here.
2 Text Recognition: Selected control function for this camera channel.
5 Teaching In: This button will begin the teaching process for the reference text.
6 Reference Text: The taught-in text according to which the products will be
inspected.
7 Reading Orientation: The orientation of the text to be read must be entered
here. This information is required for the teaching process. Orientations of 0°,
90°, 180°, and 270° are valid.
8 Maximum Distortion: Enter the allowed distortion measured for the reference
product up to a maximum of 10°.
9 Teaching In Characters: Use this button to teach additional characters. Enter
the text into the search area using the on-screen keyboard.
10 Manage Characters: View and delete previously taught characters.
11 Symbol Map: Previously taught characters are displayed here in alphabetical
order.
12 Inverse: Enable this feature if you would like to inspect light font on a dark
background.
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♦ Setting Up Text Recognition

During text inspection, text on presence and concordance will be checked
against a taught text.
In order to be able to optimally work with the text recognition, the offset
between the start light barrier and the image recording should be kept as
small as possible. This will ensure significantly fewer variations between
the individual images captured.
You can easily adjust these settings as follows:

Set the camera to Live Image. Carefully run the product with the text
1. Step
under the camera. If the text that you want to inspect is completely inside
the frame, stop. Now, mechanically convert the light barrier so that it
turns directly to the product beginning (see image below).
Now, you can set the camera's offset to 0mm in the "Data / Camera"
menu. As soon as the light barrier detects the product when the machine
is running, a picture will be taken from the desired text area.
1: Camera lens and position of
the image.
2: Text to be inspected.
3: Direction of the product.
4: Camera's start light barrier.
5: Light barrier's focal spot.
6: Mechanical adjustment.
If the selected image section is visible on the smallest possible camera
image offset, you can choose the Pattern Recognition control task and
adjust the search area. You can draw a new search area and move,
2. Step reduce, or enlarge it. During text recognition, the search area should
optimally lie around the text so that no other symbols are included in the
search area. The search area can be changed after letters within the
area have been taught.
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If the search area is at the desired location, more settings must be

adjusted.
Set up the orientation of the text in
this field. Orientations of 0°, 90°,
180°, and 270° are valid.
Set up the maximum rotation
tolerance, up to a maximum of 10°, in
this field.
3. Step Teach the text using the left mouse
button. Display and delete previously
taught symbols with the right mouse
button.
In this display, previously taught
symbols are displayed and
alphabetically sorted according to
case.
Check this button if you want to read
light text on a dark background.
4. Step have been set up or will not be needed, you must perform one final
programming drive. To do so, click the blue button, which you can find in
the Setup mode on the lower button. A message will appear.
5. Step
up to show that the system is in programming mode. Only let one
6. Step
ready.
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♦ Limitations during Text Recognition

During text recognition, observe the following points:
Only one line can be taught and managed.
We recommend that you manage no fonts measuring more than 30 pixels in
height. This minimum size will be necessary to ensure sufficient differentiation
and therefore a reliable distinction between the individual letters.
The font must have an alignment of 0°, 90°, 180°, or 270°. Diagonal fonts cannot
be managed.
No other objects may exist in the search area. Additional objects could drastically
increase the analysis time and lead to faulty evaluations.
The program will recognise spaces, but they will not flow into the evaluation. If
you teach "baumer hhs" as a reference, "baumerhhs" as well as "b a u m e r h h
s" will be correctly evaluated.
Not all special symbols can be managed. Select another section of text to inspect
if you have problems teaching and recognizing special symbols.
If all symbols have not been taught, similar symbols cannot be distinguished from
each other (for example, the symbols "6" and "8" or "I" and "i"). The program can
only provide a match for previously taught symbols. If only an "I" has been taught
but the control function detects an "i", the "i" will be evaluated as "I" with
approximately 80% concordance.
In case difficulties occur when teaching symbols, for example, symbols are left
out or two combined to one, then try to teach the symbols individually.
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Statistics and Production Data

♦ Statistics
The statistics menu gives you an overview of defective products that were
produced and the type of error that occurred. Create and save production reports
starting on this page.
1 Overview: Displays the total system counter. Die Statistik bezieht sich auf alle
Module.
1a Error-free produced products

1b Faulty products
1c Ejections
1d Length errors
2 Error Statistics Code Surveillance: If a code reader is available in your
system, the errors will be listed and sorted according to channel and error type
here.
2a Connected sensor type

2b Sum of faulty products on this channel
2c Code reading error: Code was not read or was incorrectly read
2d Colour Error: Colour of a code beam is outside the tolerance
2e Length Error: Product length is not within the tolerance
2f Lateral Register Error: Product is not feeding correctly.
2g Longitudinal Register Error: Code is not at the right position.
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3 Error Statistics Camera Surveillance: The various error types for camera
control will be listed and sorted here according to channel.

3c Error Control: The result of the setup control task was poor
3d Signal Processing Error: No associated result was found for these products.
The control task has taken too much time and the evaluation result arrived too
late.
3f Allocation Error
3g Symbol of the selected control task
4 Error Statistics Nozzle Glue Surveillance: If a G8 glue surveillance model is
available in your system, the errors will be listed and sorted here according to channel
and error type here.

4c Glue Error: not enough glue
4d Glue Error: too much glue
4f Allocation Error
5 Graphics: A graphic description of the statistics.
5a The pie chart shows the distribution of good products (green) and faulty products
(red).
5b The bar graph shows the distribution of errors on the connected modules.
Error History
Open a submenu to display the last 10 errors with time stamps

and error channels using this button.
Reset Counters
Reset the product counter using this button.

PDF Menu
Use this button to open a menu to preview the production report.

The report can be saved as a PDF.
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♦ Keys in the PDF Menu

You can view a preview of the production report and use it to create a PDF
document using this menu item.
Zoom In
You can enlarge the print display using the Zoom In key.
Zoom Out
You can reduce the size of the document display using the
Zoom Out key.
Create a PDF document
Creates a PDF document of this preview. The document will

be saved in the "statistics" subdirectory in the installation
directory.
Data Transmission
Opens a window to transmit PDF data from the system to a

USB drive. The USB drive will be searched for as a standard
setting on the E: drive.
Custom Header
Use this button to individually match the report headers.
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♦ Production Data Acquisition
Example for anaylsis of data in Microsoft Excel. One flag imports data at any
given time. A second flag visualizes the input instantly. Xtend2 provides data in
CSV format to the customer together with open description.
♦ Network connection
Additionally to the function described above, you can see several settings of the
Xtend functions from any network PC. But you can modify only some of them.
Provided that the Xtend² system is connected correctly to your PC-network, you
will need additional software installed locally. This software is then supplied with
data from the Xtend system.
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♦ Error History
The error history displays the product number, time, and cause of the last 10
errors.
1 Time: The time the error occurred.

2 Product Number: The number of the faulty product.
3 Error Location: The location the error occurred and the channel number on
which the error appeared.
Update Counter Reading
Press this button to update the display.
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Error Detection
The controller is equipped with several diagnosis tools. In test mode "diagnosis"
you can see the state of inputs and outputs on screen.
The diagnosis display provides you with important status information which, in
the event of a problem, allows you to isolate or rule out a sensor failure.
LB shows, if the integrated light barrier (LB=Light Barrier) of the sensor or an
external light barrier detects a product (green light).
I/O = Plug control shows, if the device detects a plug connected such as sensor
or external light barrier.
ATTENTION !
Only use fuses with the release current.
See Technical data.
LEDs adjacent to the connecting plugs indicate the presence of the control
voltages. This allows to check operation of inputs, outputs and power supply
without use of measuring devices.
ATTENTION !
Further electrical troubleshooting may only be done by Baumer hhs
personnel obeying safety measures. To improve service please tell the
technician the software version. You will find it in the upper left corner of
the DIAGNOSIS screen.
Device can not be started

• Unplug device from power
• Replace main fuse in plug
• In case of repeated fuse release, contact specialized personnel.
You can not modify some parts on screen

- Ask your supervisor for the password. Several settings are not open to the
public.
Guns operate in test mode, but do not in production

• Check active glue model, check dependence on machine speed
• Check gun activation
• Check impulses from encoder (Does the displayed speed on start screen
oscillate?)
• Check Start impulses (Are guns and sensor assigned correctly? Is the state of
the sensors displayed in diagnosis menu?).
Only every second product is glued

• Check the loaded glue pattern, dependence on the window. If the ‘window’
value is too large, the device does not recognise the front edge of the next
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product. Rule of thumb: Window masking smaller than or equal to product

length.
Glue errors occur at high speed

With increasing speed the glue lines are more or less displaced from desired
position?
• You can compensate the time of gun activation and flying glue. To get there
press the following button: “COMPENSATION”.
The glue line is wrong in slow machines but correct in high speed?
• First set up ENCODER, than OFFSET and then COMPENSATION.
Controller does not save glue pattern

• The controller needs at least one glue line to save a pattern. Patterns without
glue are disapproved.
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Camera system troubleshooting

Camera produces a live Incorrect encoder setting (speed is not
image, but no triggered displayed)
image Missing and/or wrong assignment of the starting
light barrier.
Plugs on the camera module are not screwed
tight
Ejector opens at the wrong No programming drive was executed after setup
moment, or not at all Ejector is not activated
Defective products are not Image is too bright
ejected during the blank Image is too dark
sheet check
Machine parts protrude into the search area
Defective products are not Machine parts protrude into the search area
ejected during the logo
comparison
Camera image is out of focus The camera height above the product has been
changed, but the focus was not adjusted
afterwards
Live image cannot be The system is still set to production mode (the
switched on green lamp on the traffic light is lit)
You are not logged in with the correct user level
No monitoring tasks can be The system is still set to production mode (the
set up green lamp on the traffic light is lit)
You are not logged in with the correct user level,
or you do not have not the appropriate user
rights
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Diagnosis
Manually flush the valves, check the functionality of the inputs and outputs in test
mode, and filter malfunction causes here. The software versions of individual
system components will be displayed in the header.
Dots Test Mode
The individual valves can only be manually triggered using

the upper buttons when this or when the button for "Flush
Test Mode" is activated. The valves function in dot mode as
long as this test mode is activated.
Flush Test Mode
The individual valves can only be manually triggered using

the upper buttons when this or when the button for "Dots
Test Mode" is activated. The valves open permanently as
long as this test mode is activated.
1 Glue Valve Activation: Individually direct the valves towards test purposes if
you have activated one of the test buttons in the footer.
2 Glue Dot Frequency: If you have selected dot glueing for the rinsing process,
you can preselect the frequency for the dots here.
3 Preset Pump Pressure: If you have installed an appropriate pump, you can
set a glue pressure for the pump for testing purposes. The current pressure can
be read in the field next to it on the right.
4 Diagnosis Glueing CPU: The yellow indicator lights show the status of the
CPU glueing inputs and outputs. The abbreviations S1 to S8 show the start light
barriers' input signals. Other relevant inputs and outputs are represented by the
respective names at their connections
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5 Test Module Function: Test inputs and outputs of the camera model and the
camera here if you are in the "Setup" operating mode. When pressed, the buttons
5a and 5b check the camera outputs for the correct transmission of a good or
bad signal. The yellow indicator light is active when the signal has been
transmitted. The statuses of the start inputs as well as the module encoder inputs
will be displayed on the right side.
Filter Change
This button is used to reduce pressure in electric material

pressure regulators if the pump filter needs to be serviced.
The filter change can only be initiated when the button for
"Rinse Test Mode" or "Dot Test Mode" is enabled.
Pay attention to the directions appearing on the screen

when changing the filter!
The pump pressure will be lowered completely when

activating the filter change. Open the valves in rinse mode in
order to discharge the remaining pressure. Only then should
the filter casing be opened. Now you can perform
mechanical maintenance on a non-pressurised system.
Press "Filter Change" again after you have carried out the
filter change and the filter casing is tightly closed. This will
end the filter change maintenance mode and the pressure
will rise to the target pressure.
Test Ejection
Press this button to force a test discharge. The next product

passing the ejector / labeller will be ejected or labelled even
if it exhibits no errors.
CAN Errors
This button is only visible if a CAN error has been recorded.

Using this button, the service personnel can read error
messages.
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Cleaning and care

To clean the touch screen from normal grease spots, use soft wetted cloth for
eyeglasses. Baumer hhs urgently discourages from use of detergents, wet and
scratching cloths.
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Spare Parts Controller
Spare parts basic cabinet

75900024
Pos Order-no. Piece Description

1 96216740 2 Power supply
2 96216741 1 UPS controller
3 96216742 2 Battery for UPS
4 96226111 1 Timer relay
5 96144101 1 Mains filter
Bus connection module, X-comp. - Slave IN
6 75909300 1 connection
7 79209132 1 Camera module
8 75909310 1 Bus connection module, Master OUT terminator
9 79931035 1 MIL9 Dongle USB
10 75909500 1 Flash controller
11 75909101 1 Cable, strobe controller – cam module
Protective earth present
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Spare parts camera set TXG03

10328210
pos order-no. piece description

1 79931040 1 Matrix camera VGA GIG-E
2 79209179 1 Objective 6mm
3 96216693 1 Ring lighting
4 79029450 1 TXG camera housing
5 89315018 1 Holding pole
6 89315100 1 Crossbeam clamp
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Spare parts : connection set display XTS2 ALU DVI 5m

74911291
pos order-no. piece description

1 74911180 1 cable USB 5 m
2 74911170 1 cable DVI 5 m
3 74911211 1 power cable XTS2 Term, 5 m
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Electrical Circuit Diagram
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10. Appendix
Warranty and Repairs
Warranty
Baumer hhs GmbH grants the original purchaser a warranty on these devices
which have been developed and manufactured in accordance with the latest
state of the art. The warranty extends from the commissioning of the devices for
a period as required by law.
The warranty covers:
• Function
• Material
• Workmanship
Excluded from the warranty are normal wear and/or wearing parts. The warranty
terms of the particular subcontractor apply in the case of complete
subassemblies etc. which have been bought in by Baumer hhs.
Our general terms of sale and delivery apply.
Rights under the warranty cease in the case of:
• improper handling
• repairs carried out by third parties
• Fitting of parts other than original parts
In the case of work under warranty, it is at the discretion of Baumer hhs as to
whether parts etc. should be repaired or replaced. Claims under warranty going
beyond the above are excluded since we can exercise no control over the proper
use and handling of the device.
Repairs
Repairs may only be carried out by experts using original spare parts. This
clause applying in particular in the case of work on electrical equipment.
Accordingly and for the safety of all concerned, a defective device should be
returned to Baumer hhs. We will repair it professionally and take into account
thereby all the relevant safety instructions. Should you have any questions,
please contact our headquarters or one of our agencies.
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10. Appendix
Baumer hhs - Adhesive application with a proven

systems
Value added for you and your customers
No matter whether you are involved in print finishing, packaging manufacture,
woodworking or in custom machinery, we conceive and supply you the
technology which gives you a competitive edge. With our glue application
systems you will broaden your product array and reduce your customers'
manufacturing cycle. The value added chain is lengthened automatically.
System Central for Glue Application

The four components of the Baumer hhs glue systems leave nothing to be
desired. You give us your requirement and we give you the answers. Our
concept of modularity is such that you get a maximum of effectiveness with a
minimum of effort. Buildable user-friendly technology with us is not lip service, but
a daily commitment.
Since 1986 hhs Gluing Systems GmbH has become your glue system partner
and problem solver with worldwide scope dedicating themselves to being a
solution provider for your specific needs. Whether hotmelt adhesives or cold
dispersion glues, Baumer hhs offers custom tailored systems for your
applications.
Sticking to the target

Over the years Baumer hhs has become known for its ability to analyze a need
and apply its experience and knowledge base to arrive at a well-targeted, safe
and quick solution for mechanical adhesion challenges.
It all starts with an exchange of ideas

It all starts with an exchange of ideas and continues with the application of
development and production principles such as precision, superior service. This
constructive give and take is the basis for crafting custom made solutions to your
production needs.
Our sales and technical departments cooperate in the specification and
adaptation of product to need to arrive at an answer for you. They follow your
project as a team making sure after sales service quality matches the design and
operation level. Consult our international sales service network.
first contacts can be fleeting

We know that the first contacts can be fleeting if our approach doesn't cement a
relationship immediately…with high quality products and 360 degree service.
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10. Appendix
Alphabetical Index
Analysis ............................................... 95 CE mark ............................................ 7
Blank sheet Menu ................................................... 43
Operating elements ......................... 42 Network ............................................... 95
Buttons ................................................ 35 Offset .................................................. 45
CAM Operating elements ............................ 35
Connector ........................................ 30 Option
Camera Connector.................................. 29, 30
Operating elements ......................... 39 padlock symbol ................................... 62
Cleaning ............................................ 102 Password ............................................ 62
Code Pattern
design .............................................. 71 Operating elements ......................... 42
Operating elements ......................... 41 Pharma-Code ..................................... 73
Code creation ...................................... 71 Pictograms
Commissioning Camera modul ........... 46 Visible.............................................. 19
Connectors Safety
CAM ................................................. 29 Decommissioning ............................ 21
COPY .................................................. 36 Disassembly .................................... 21
Date ..................................................... 49 Perfect technical condition .............. 12
Daten Scan-300 ............................................ 29
Export .............................................. 95 Serial interface
Display ................................................ 49 RS232 ............................................. 29
Documentation Short instructions
Languages ......................................... 8 Camera operation ........................... 69
DONE .................................................. 36 Signal light .......................................... 30
Drying glue .......................................... 52 Software
Electrical Circuit Diagram .................. 107 Code design .................................... 75
Encoder ......................................... 53, 54 Spare parts
Encoder input ...................................... 30 basic cabinet ................................. 103
Equipment camera set .................................... 105
Cleaning agents............................... 13 connection set display XTS2 ALU DVI
ESC ..................................................... 36 5m.............................................. 106
External light barrier Standard-Code ................................... 72
Connector ........................................ 29 Start sensor
Flash ................................................... 30 at downtime ..................................... 61
Folding machine Status
user interface ................................... 25 Connector........................................ 30
Hole filter ............................................. 61 System
Initial operation Description ...................................... 23
Glue pressure ................................ 46 Tacho .................................................. 53
System settings ............................. 49 Technical data
Kamera................................................ 26 camera ............................................ 27
Keys .................................................... 35 Technical Data
Language ............................................ 49 display XTS² Alu VGA 5m ............... 28
Light Time .................................................... 49
Connector ........................................ 30 Timne stop .......................................... 52
Light barrier ......................................... 45 Troubleshooting
Light CTRL Camera system ............................... 99
Connector ........................................ 30 User level ............................................ 62
Machine stop ....................................... 30 Warranty ........................................... 109
Machinery Directive
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10. Appendix
Contact / Kontakt
EUROPE Slovenia, Croatia, Macedonia ASIA, OCEANIA
DZS grafik d.o.o.
Finland Ulica Jozeta Jame 12 Australia, New Zealand
Pakap Finland Oy SI-1210 Ljubljana-Sentvid, SLOVENIA Powered Innovations
Kumitehtaankatu 5 +386 1 5483222 Unit 42, 93-97 Newton Road
04260 Kerava, FINLAND [email protected] Wetherill Park NSW 2164 AUSTRALIA
+358 68 995 100 +61 2 9616 7200
[email protected] Sweden, Denmark, Norway [email protected]
hhs Skandinaviska AB
France, North Africa Magasingatan 1 China, Taiwan
Baumer hhs S.A.R.L. 26538 Åstorp, SWEDEN Baumer (China) Co. Ltd.
Rue du Loure, ZI +46 42 300 90 20 Building 11, No.
01600 Reyrieux, FRANCE [email protected] 1525 Minqiang Road,
+33 474 087 878 Songjiang Industry Park,
[email protected] Spain, Portugal 201612 Shanghai, CHINA
Baumer hhs GmbH +86 21 3701 8835
Germany, Austria, Adolf-Dembach-Straße 19 [email protected]
Switzerland, Benelux 47829 Krefeld, GERMANY
Baumer hhs GmbH +34 93 184 56 40 India, Sri Lanka, Bangladesh,
Adolf-Dembach-Straße 19 [email protected] Bahrain, Iran, Iraq, Jordan,
47829 Krefeld, GERMANY Kuweit, Lebanon, Oman, Qatar,
+49 2151 4402 0 Turkey Saudi Arabia, Syria, UAE, Yemen
[email protected] BTS Matbaa Malzemeleri Baumer India Private Limited
San. Dış. Tic. Ltd. Şti. Fourhum Centre
Greece Yüzyıl Mahallesi, MASSİT Matbaacılar Sitesi S. No. 112/2/21, 112/2/64 + 112/2/72
Kolatron 4. Cadde No:106 Opp. RMD Sinhgad Institute
Saimi 80-82, Bağcılar / İSTANBUL, TURKEY Pune-Mumbai Highway, Warje
18538 Kallipoli / Piraeus, GREECE +90 212 438 66 71 Pune-411058, INDIA
+30 21 02 847 903 [email protected] +91 20 66 292 400
[email protected] [email protected]
United Kingdom, Ireland
Italy Baumer hhs Ltd. Israel
Baumer hhs S.r.l. hhs House, Van Kloeten Ltd.
Via Resistenza 1 39 Commerce Rd, Lynch Wood Hachsharat Hayeshuv 5
20090 Assago (MI), ITALY Peterborough, PE2 6LR, UK 75706 Rishon Lezion, ISRAEL
+39 02 33 405 435 +44 1733 391 333 +972 3 96 28 606
[email protected] [email protected] [email protected]
Lithuania, Latvia, Estonia AMERICA Japan

GK TRADE A-Linkage Inc.
Jundos Str.39, Argentina, Paraguay, Uruguay No. F, Com Plaza Imagome,
LT-08402 Vilnius, LITHUANIA Walbaum Representaciones Ltda 2-2-9 Imagome, Higashi-Osaka City,
+370 67977776 (Lithuania) Vicente F. Lopez 298 14° B Osaka 578-0903, JAPAN
+371 20377776 (Latvia) 1640 Martinez (Buenos Aires) ARGENTINA +81 72 983 6161
+372 58517776 (Estonia) +54 11 4793 6044 [email protected]
[email protected] [email protected]
Korea
Poland, Czech Republic, Slovakia Brazil JNC CO.
AB System Sp. z o.o. WRoma Comercio de B-02, 330-4 Seohyun Bundang,
ul. Wolności 18 Materiais e Servicos Seongnam, Kyeonggi 461200
64-130 Rydzyna, POLAND Rua Manoel Saldanha SOUTH KOREA
+48 655 380 011 de Castro 188-Lj. +82 31 608 8663
[email protected] Sao Braz - 82315 Curitiba, BRAZIL [email protected]
+55 41 3372 1580
Romania [email protected] Singapore, Malaysia, Indonesia,
CD Sensoric Philippines, Thailand
Str. Prof. Dr. Aurel Popa nr. 5 - 7, Chile Mac Craft Pte. Ltd.
550077 Sibiu, ROMANIA Walbaum Representaciones Ltda. Lam Soon Ind. Bldg.
+ 40 269 253 333 Perez Valenzuela 1520
63 Hillview Avenue 10-18
[email protected] Of. 304 Providencia 2366 Singapore, SINGAPORE
Santiago, CHILE
+65 676 21 500
Russia +56 22 23 51 020
[email protected]
Terra Print [email protected]
Elektrodny pr. 6, off. 55, AFRICA
111123 Moscow, RUSSIA Mexico, Central America
+7 495 36 30 078 SICA, S.A. de C.V. South Africa
[email protected] Pedro Luís Ogazón No. 33, Trisave (PTY) Ltd.
Col. San Angel, P.O. Box 1153
Masterkley 01000 México, D.F., MEXICO 7915 Cape Town, SOUTH AFRICA
Dmitrovskoe sh., d.100, str. 2 +52 55 53 223 600
+27 21 44 77 030
127247 Moscow, RUSSIA [email protected] [email protected]
+7 495 63 80 934
[email protected] USA, Canada
Baumer hhs Corp.
10570 Success Lane
Dayton, Ohio 45458, USA
+1 937 88 63 160
[email protected] 11/2014
112 28.11.2014 10328260-EN-20141125.docx

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© 2014 Baumer hhs GmbH

Tel.: +49 21 51 - 44 02-0

Handling and Operation ...................................................................31

♦ Setting Up Pattern Control .............................................................81

Eliminate faults immediately, especially those that pose a risk during

This controller is provided with the CE mark.

Notes on the documentation

This operating manual is a part of the machine.

♦ Care when reading

Clarification of Warning Instructions

Clarification of the warning and information instructions used.

HAZARD highest priority, when not followed: certainly danger of injury

Work may only be entrusted to persons who are:

- Over the age of 18

The particular safety and accident-prevention regulations applying for

Using the machine

Perfect technical condition

National laws and regulations

Personal protective equipment

General operator duties

Responsibilities during assembly, commissioning, operation and repair works

Life phases of the machine / operating modes

The following life phases are thereby distinguished:

• Transport, assembly and commissioning

Only qualified personnel may be assigned to the corresponding work.

Safety during transport, assembly and commissioning

The following applies to the electrical connection and cabling work:

• Only qualified personnel may work on electrical installations.

The following applies to the operation and use of fittings:

Safety during production

Operating must be ceased immediately if

Safety during maintenance, repairs

DISCONNECTED FROM THE POWER SUPPLY:

Safety during disassembly and decommissioning

The correct suitable protective equipment must be worn.

Only carry out disassembly or decommissioning work if a second worker is

Personal Protective Equipment

Functional Description of Xtend² Series

The fact that it is possible to manufacture various production pieces on one

Example of functional module block

Xtend² Folding machine

Camera module function

Code Reading of 1D & 2D codes

Mustererkennung Pattern recognition

Texterkennung Reading of text (yet not implemented)

Schimmelbogen Checking for the presence of printing

Technical data camera module

Technical Data display XTS² VGA BG-15“

- type ........................................................... Touchscreen

Transport and Assembly

Connections – ‘CODE & CAM’ glue monitoring module

Handling and Operation

1 Submenu Camera Surveillance: By clicking on the camera or the symbol for

Glueing Symbol Key

Glue Surveillance Symbol Key

(green) Sensor activated. The last product was correct.

(red) Sensor activated. The last product was faulty.