RYO FILLING STATION REFERENCE MA by fjwuxn

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									      RYO FILLING STATION
REFERENCE AND TRAINING MANUAL
         RYO FILLING STATION
         REFERENCE MANUAL



 Congratulations on your purchase of the RYO Filling Station. This innovative machine will
increase your profits and make your store a destination stop for smokers who are searching
 for a way to save money. And because RYO Machines has guaranteed exclusivity, you will
                continue to be the only company who has one in your area.

 This manual was designed to ensure that you will get optimum performance from your
machine. It addresses several aspects of execution and maintenance so it will roll perfect
                            cigarettes each and every time.



                                       RYO Machines
                             1845 North State St., Girard, Ohio
                         Phone: (330) 646-1118 Fax: (330) 545-5995
                                 www.ryofillingstation.com
     TABLE OF CONTENTS
PAGE                  CONTENT
 1           Selecting Tobacco and Tubes
 2           Ordering Tobacco and Tubes
 3            Using the Moisture Meter
 4              Using the Digital Scale
 5     Proper Storage of Products and Equipment
 6                Daily Maintenance
 7           Batch Ordering and Reloading
 8            References and Passwords
 9         Optical Sensor Location Diagram
10              Gear Location Diagram
TABLE OF CONTENTS (CONT.)
 PAGE                     CONTENT
  11               Motor Reference Chart
  12              Cylinder Reference Chart
  13       Pneumatic/Reed Switch Troubleshooting
  15              Alarm List and Solutions
  24            Glossary of Terms with Images
  31    Further Documentation and Warranty Information

  32                 General HMI Screens

  44          Owner and Technician HMI Screens
 SELECTING TOBACCO AND TUBES
 Failure to follow our recommendations for products to be used with the RYO Filling Station will render your warranty null
                                                        and void.


• Selecting Tobacco
    We strongly recommend the use of Kentucky Select or 1839 brand tobacco. These brands are
    recommended because the cut and texture of their tobacco consistently works best. The more
    consistency you develop with your process the better the process becomes.
    * In the future more brands of tobacco may become recommended. To get an updated list of our recommended tobacco
    brands please call us at (330) 646-1118.

    All flavors of tobacco work well, with the exception of menthol. Menthol tobacco should never be used
    with the RYO Filling Station. Menthol tobacco has a sticky texture that will not allow it to work properly
    in the machine. If the customer desires a menthol cigarette, they can use menthol flavored tubes with
    non-menthol tobacco.


• Selecting Tubes
    We strongly recommend the use of Hot Rod Tubes. This brand is recommended because they
    consistently have a round shape along the entire tube which works well with the machine.

    All flavors of king size tubes work well, including full flavor, light and menthol.
    * The RYO Filling Station does not roll 100s, it only rolls king size tubes.



                                                                                                                             PG. 1
 ORDERING TOBACCO AND TUBES
• Ordering Tobacco
  To order Kentucky Select or 1839 brand tobacco please contact:

  U.S. Flue-Cured Tobacco Growers
  250 Crown Boulevard
  Timberlake, North Carolina 27583
  Phone: (919) 821-4560
  Fax: (919) 821-3691
  www. ustobaccofarmer.com

• Ordering Tubes
  To order Hot Rod Tubes please contact:

  Turbomatic Machines and Tubes
  10825 Medallion Drive
  Evandale, Ohio 45241
  Phone: (877) 318-8726
  Fax: (513) 794-0570
  www. turbomaticmachines.com



                                                                   PG. 2
    USING THE MOISTURE METER
• Using the Moisture Meter
  The moisture content in tobacco can vary greatly, even between different bags of the same brand. Tobacco must have the
  proper moisture content to roll properly in the RYO Filling Station, tobacco that is too moist or too dry will not yield the
  desired results. Luckily this is something that can be easily solved.

  Your machine comes with the Delmhorst BD2100 Moisture Meter. Using it daily is essential for rolling good cigarettes
  consistently.

  To prepare your tobacco for the next day’s use you should take a moisture reading by sticking the two prongs of the
  moisture meter firmly into the tobacco. While the prongs are still inserted into the tobacco press the button marked with
  a droplet. This will display the moisture value on the screen. Take multiple readings to get an average value. If the
  moisture value’s range is between 12 and 16 optimal.
  If the tobacco’s moisture value is below 12 or above 16 do NOT use it.

  If the tobacco is too wet (the value is above 16), it will take approximately a day or two to come into range. Keeping the
  tobacco in tobacco bins (tobacco bins will be covered on page 5) and taking readings at least 24 hours prior to using it will
  insure good, usable tobacco for your customers.

  If the tobacco is too dry ( the value is below 12), it will take approximately a day or two to come into range. Placing the
  tobacco in a humidor, or placing a water pillow inside the tobacco container will raise the moisture value.

  It is important to care for your moisture meter to insure that it stays in the best working condition. To do so, please read
  the manufacturer’s instruction manual that is provided.

  NOTE: Occasionally the hygrometer can build a charge up inside of it which gives you grossly inaccurate readings. If you
  notice this it can be fixed by using the following steps. First remove the battery from the hygrometer. With the battery
  removed hold down the “water droplet” button for 15 seconds and then the “checkmark” button for 15 seconds. After this
  insert the battery again, but only plug in one contact at a time. If these steps are followed correctly the charge inside
  should be depleted and the hygrometer should be in working condition again.
                                                                                                                                  PG. 3
          USING THE DIGITAL SCALE
• Using the Digital Scale
  Your machine comes with the Dodo mini-digital scale. Frequent use of the scale is necessary to insure
  that cigarette weights are acceptable. Properly rolled cigarettes should weigh between 1.1 and 1.2
  grams. The weight can be adjusted to individual preference by adjusting the compression value in the
  HMI Production screen with the “More Tobacco” and “Less Tobacco” buttons. These buttons are also
  covered in the HMI Training Manual.

  When using your scale be sure it is set to grams mode. Do this by pressing the on/off button. Then press
  the mode key to toggle the arrow to the grams setting. This may need to be done whenever you power
  on the scale.

  Also, make sure that the display is set to zero before placing a cigarette on the scale. It will take a few
  moments after powering on for the scale to display zero. Failure to wait for this will lead to an incorrect
  reading. Be sure to keep the scale on a flat horizontal surface to insure correct readings.

  It is important to care for your scale to insure that it stays in the best working condition. To do so, please
  read the manufacturer’s instruction manual that is provided.




                                                                                                                   PG. 4
 PROPER STORAGE OF PRODUCTS
       AND EQUIPMENT
• Storing Tobacco
   We recommend that all tobacco is stored in plastic air-tight bins. These bins should have the package
  labels of the tobacco they contain and the Surgeon General’s warning clearly displayed in view of the
  customer. If a bin needs to be refilled this should be done in the presence of the customer who
  requested the tobacco. These bins should help regulate the moisture levels of the tobacco which will in
  turn make the rolling process more seamless and enjoyable.

  Tongs should be used to remove the tobacco from the bins. These tongs should be kept clean for the
  safety of your customers.

  When tobacco is removed from these bins it is important for it to be measured. Either a store employee
  or store customer can measure it. The weight should be approximately 8 oz for the best result. Number
  12 paper bags are ideal for this.


• Storing Equipment
  All equipment should be stored and cared for according to the manufacturer’s manuals that are
  provided. It is important that all equipment is kept clean for the safety of your customers.




                                                                                                            PG. 5
                 DAILY MAINTENANCE
• Clean the Dust Inside of the Machine
  It is recommended to clean the dust from the inside of the machine with a vacuum. While using the
  vacuum be careful not to misalign any of the sensors or parts.

• Empty Water from the Compressor
  The water can be drained from the compressor by releasing the compressor drain valve located on the
  bottom front of the machine. This only applies to machines which have compressors mounted internally.
  Otherwise, you will have to release the drain valve located on the compressor itself.

• Empty Water from the Air Filter
  The water can be drained from the air filter by moving the blue slider valve located on the air filter unit.
  This unit is located on the top left of the machine.

• Empty the Vacuum Bag
  Open the vacuum chamber on the side of the cabinet. Inside will be a vacuum bag that is secured by
  an elastic band. Simply remove the bag, empty it, and place it back on.

• Clean All Optical Sensors
  Wipe these sensors gently with rubbing alcohol on a soft cloth, paper towel or cotton swab. Please
  refer to the diagrams on Page 9 if you’re having trouble locating the sensors.

• Clean the Cutting Blade
  Wipe the cutting blade gently with rubbing alcohol on a soft cloth, paper towel or cotton swab to
  remove any leftover tobacco.

                                                                                                                 PG. 6
BATCH ORDERING AND RELOADING
• Batch Ordering Process
   Please call RYO Machines at (330) 646-1118 to order more batches for your machine. Each batch consists
   of 200 cigarettes. Be sure to have your credit card information ready when you call.

   It is recommended to set aside some time for when you plan on ordering batches. Immediately after
   ordering you will then have to reload your machine over the phone which is outlined below. It is also
   recommended to order batches in advance so that your machine is never down for your customers.

• Batch Reloading Process
  After ordering your desired amount of batches you will then have to load them into your machine. This
  will be done over the phone with an RYO Machines employee.

  Prior to calling you will need to access the Setup Screen on the HMI and then click on Reload. If you have
  trouble doing this you can get directions over the phone as well. Once you are on the setup screen
  please call RYO Machines to place your order. Credit Card information will be required for this process, as
  outlined above.

  The employee will then have you read multiple values to them over the phone. These values are listed
  on the left side of the screen under the “Machine Code” column. Be sure to speak loudly and clearly. Feel
  free to use the phonetic alphabet table on page 8 to simplify the process.

  After this the employee will then read you multiple values that you will then need to enter in the “Entry
  Code” column on the right side of the screen. After this, it is recommended that you double check all of
  the values to make sure they are correct. When satisfied click on validate. You will now have your newly
  purchased batches and can continue using the machine.
                                                                                                              PG. 7
          References and Passwords
• Reference Tables
                                                                                   Letter          Phonetic
                                                                                     A      Alpha

                                                                                     B      Bravo
  To the side is the NATO Phonetic Alphabet. If you are having problems              C      Charlie
  understanding an RYO employee during the batch reloading process, or they          D      Delta
  are having trouble understanding you, feel free to refer to and use this tool.     E      Echo

                                                                                     F      Foxtrot


• Passwords                                                                          G

                                                                                     H
                                                                                            Golf

                                                                                            Hotel

  Occasionally the RYO Filling Station may ask you for a password to access          I      India

  employee-only screens. These passwords are set in place as a security              J      Juliet

  precaution to stop the accidental changing of the machines settings. The           K      Kilo

  passwords it will ask for are below:                                               L      Lima

                                                                                     M      Mike

  Level 1 Password – “123“                                                           N      November

  Level 2 Password – “911”                                                           O      Oscar

  Level 3 Password – “852”                                                           P      Papa

                                                                                     Q      Quebec

  Electronic guides of both this manual and the Training Manual are available        R      Romeo

  on our website located at www.ryofillingstation.com. The passwords needed          S      Sierra

  to download these manuals are as follows:                                          T      Tango

                                                                                     U      Uniform

  Reference Manual – “refmanual1779”                                                 V      Victor

  Training Manual – “trainingmanual3981”                                             W      Whiskey

                                                                                     X      X-ray

                                                                                     Y      Yankee

                                                                                     Z      Zulu
                                                                                                              PG. 8
      Optical Sensor Location Diagram
Below are images that may be helpful to reference when you’re looking for the sensors that should be cleaned daily.




     Sensor #                                                                                 Cleaning Instructions

        1       Sensor 1 is a blue optical sensor that detects the cassette. It has a lens on the bottom that can be cleaned with a cotton swab.

                Sensors 2 and 3 are black optical sensors that detect the level of tobacco currently in the machine. You will have to unlatch the conveyor assembly and reach inside the
       2, 3
                black chute to locate the lenses on these. This process was covered in detail in your training. They can be cleaned with a cotton swab.

                Sensors 4 and 6 are gray cylindrical optical sensors. Each one has a lens on the end of the sensor that opposed the wire. These sensors detect white paper tubes near them.
       4, 6,
                These can be cleaned with a cotton swab.

                Sensor 5 is a gray cylindrical optical sensor. The lens is located on the end of the sensor that opposes the wire. This sensor is confined too tight to clean with a cotton swab.
        5
                You will need to clean it with a cloth or tissue.

                Sensor 7 is a sensor identical to Sensors 4 and 6. It also serves the same function. However, it is recessed in the Tube Loading Chamber making it hard to see. Simply take a
        7
                cotton swab and run it along the slot leading to the Tube Loading Chamber to clean it.

                                                                                                                                                                                               PG. 9
          Gear Location Diagram
         Below are images that may be helpful to reference when you are looking for
                               recommended greasing spots.




Use a cotton swab to apply lithium grease to the encircled spot pictured above.
Periodically check the gears to see if more grease is needed. The grease will help
ensure the lifespan of the gears.
                                                                                      PG. 10
                Motor Reference Diagrams
                  Below is a reference chart detailing the polarity of each of the motors.
  Legend          Wiring these motors incorrectly may cause damage to your machine, so
      Neutral     it is important to refer to this chart if you ever find yourself unhooking
      Hot         these motors. Be very careful when attaching and detaching these wires
                  from their contacts. The contacts are very fragile.

 Motor       Polarity          Motor           Motor        Polarity            Motor
Number      Reference          Name           Number       Reference            Name

                           Tobacco Dozer
 M1
                               Belt              M3                       Tube Shaker Cam




                            Tobacco Pre-
 M2                                                                            Cassette
                              Feeder             M4
                                                                              Positioner



                                                                                           PG. 11
            Cylinder Chart Reference
            Below is a chart to reference when trying to identify specific cylinders and their
                                              functions.

Cylinder Label    Cylinder Name                                     Cylinder Function
                                           The Tobacco Former Cylinder controls the blade which cuts the tobacco
     C1-2            Tobacco Former
                                           before it is injected into a paper tube.
                                           The Tube Loading Cylinder pushes paper tubes out of the cassette area and
      C3               Tube Loading
                                           onto the transfer tubes located on the drum.
                                           The Ejector Cylinder ejects all good, finished tubes from the machine into
      C4                 Ejector
                                           the chute for the customer to receive.
                                           The Rejector Cylinder ejects all bad tubes from the machine into the vacuum
      C5                 Rejector
                                           chamber for disposal.
                                           The Flush Door Cylinder controls the opening and closing of the door above
      C6                Flush Door
                                           the tobacco chute so that no tobacco will spill out during production.

      C7                 Indexer           The Indexer Cylinder controls the rotation of the drum during production.

                                           The Injector Cylinder injects each paper tube with tobacco when they are in
     C8A                 Injector
                                           the correct position on the drum.
                                           The Stopper Cylinder controls the black stopper that keeps the paper tubes
     C8B                 Stopper
                                           in place on the drum while they are being injected with tobacco.
                                            The Tube Former Cylinder controls the rod with the cone attached to the tip
      C9               Tube Former
                                           that helps misshapen paper tubes load on to the transfer tubes more easily.




                                                                                                                        PG. 12
Pneumatic/Reed Switch Troubleshooting
USE CAUTION, DANGER OF INJURY OR DAMAGE
Almost all alarms relate to a cylinders function and/or the reed switches attached to it (“Reed switch” refers to the sensor that is attached to the
cylinder). You can verify the functionality of a cylinder related alarm easily by following the three steps below. Reference POINTS A-F below when
needed.
• 1. You can manually activate the valve and verify that the cylinder is moving (this is done by pressing the small button on the valve). If it
is not moving refer to POINT A. *make sure you're reading at least 80 PSI on the air pressure gauge+ *Valve Reference: “Tube…(V3)” stand
for valve number 3 (fourth from the electric plug on the manifold)].
• 2. With Step 1 working, verify that the reed switch(es) are turning ON and OFF respectively. For a cylinder with two reed switches: if the
valve is activated (cylinder extracted), the “SAFE” reed switch should turn OFF and the “OUT” reed switch turn ON. If the valve is de-
activated (cylinder retracted), the “SAFE” reed switch should turn ON and the “OUT” reed switch turn OFF (also for a cylinder with two
reed switches). If any fail, refer to POINT B.
• 3. With Step 2 working, monitor the pilot light on the problem valve. If the pilot light turns ON but the cylinder does not extract, or if
the pilot light turns OFF but the cylinder does not retract, then refer to POINT C. (Note: Valve #6 works in reverse, OFF is extracted and
ON is retracted [door opened].)

• A) This is likely a mechanical jam. Turn off the air supply by using the red air switch on the left side. Manually move the cylinder and
verify for any mechanical blockage. If everything is free to move then a faulty valve is possible (Refer to POINT C). If it interferes with the
drum that holds the transfer tubes refer to POINT D.

• B) This is likely a reed switch that became poorly positioned. To readjust a safe-position (retracted) reed switch refer to POINT E. To
readjust a out-position (extracted) reed switch refer to POINT F. If the readjustment process did not work then you can test the reed
switch with a magnet present. The reed switch should turn on when a magnet is placed against it. If the reed switch does not respond
then the reed switch is likely defective or has a bad connection in the junction box or in the main electrical panel. If this is the case, the
reed switch will need to be replaced. (NOTE: UNPLUG THE MACHINE BEFORE OPENING ANY ELECTRICAL COVER.)

• C) This is likely a valve that became defective. A replacement valve will need to be ordered and installed. This can be due to the
compressor leaking oil into the air lines, so you should inspect your air lines for oil before replacing the valve or you run the risk of it
happening again.



                                                                                                                                                   PG. 13
Pneumatic/Reed Switch Troubleshooting
C1) If the pilot light on the valve turns on and off respectively but the cylinder never moves and it is not jammed, then the valve is
“sticky”. Sticky refers to valve being activated/deactivated, but the internal spool does not move. A replacement valve will need to be
ordered and installed.

C2) If the pilot light never turns on or off you will need to go to the IO Test Page on the HMI Touchscreen. This page will not be accessible
if there is currently an alarm or if you are in production mode. You can activate valves 1 & 2 by pressing the “CUT”, INJ” or “SAFE”
buttons. For any other valve you will press the proper number (ie: P23 is V3, P24 is V4, P29 is V9, and so on). With all of this said, click the
proper valve output test button. With the button “bright” the valve pilot light should turn ON, with the button “dark” the valve pilot light
should turn OFF. Any failure can be a bad connection, a defective valve, a unplugged valve within the valve body itself, or a burnt PLC
output.

D) The indexer barrel is misaligned. To realign the indexer you will first need to make sure the air pressure is on. While the air pressure is
on you will have to loosen two screws holding the indexer drum in place. These screws are the two screws closest to the drum (out of 4
total) that are located on the black coupling that holds the drum. When looking inside the front of the machine this coupling is located
inside a metal block directly to the left of the indexer cylinder. You may need to rotate the drum a little until you can access the sockets of
the screws. Once the screws are loose you can move the drums position until it is correctly positioned, then re-tighten them. You will
know the drum is positioned correctly when you can move all three of the rods (eject, reject and injector) through the drum without
them rubbing on it or becoming “caught”.

E) The cylinder's SAFE (retracted) reed switch needs adjusted. With the air pressure off move the reed switch all the way back to the end
of the cylinder (the end closest to the cabinet wall). Extract the cylinder rod so that the safe position reed switch is OFF (unlit), then bring
it back slowly to 1/6” of an inch before it is full retracted. At this point the reed switch should still be off (unlit). Move the reed switch
away from the back of the cylinder until it turns on (lights up red). Repeat step E1 and monitor that the reed switch now turns on at 1/6”
before it is fully retracted. Repeat these steps until the proper adjustment is achieved. Once completed tighten the reed switch in place
and test it one last time.

F) The cylinder's OUT (extracted) reed switch needs adjusted. With the air pressure off move the reed switch all the way to the front of
the cylinder (the end closest to the rods). Retract the cylinder rod so that the OUT (extracted) position reed switch is OFF (unlit), then
bring it forward slowly to 1/6” of an inch before it is fully extracted. At this point the reed switch should be off (unlit). Move the reed
switch away from the end of the cylinder until it turns on. Repeat step F1 and monitor that the reed switch now turns on at 1/6” before it
is fully extracted. Repeat these steps until the proper adjustment is achieved. Once completed tighten the reed switch in place and test it
one last time. (NOTE: CALL RYO IF YOU ARE HAVING PROBLEM WITH THE INJECTOR'S OUT [EXTRACTED] REED SWITCH.)
                                                                                                                                          PG. 14
                       Alarm List and Solutions
Alarm Code               Alarm Description                                     Alarm Solution
                                                                               Check that the cabinet door is fully closed and locked. If this doesn't fix the alarm, check to
                                                                               make sure the magnet sensors at the top of the door are still present and attached
    A1                     The Cabinet Doors Are Not Closed
                                                                               correctly without a large gap between them. If there is too large of a gap between the two
                                                                               magnets they won't read correctly and will need to be moved closer together.

                                                                               Check the sensors on the tobacco former cylinder (C1-2). This is the cylinder that cuts and forms the
                                                                               tobacco. This alarm means that the SAFE and the OUT sensor are both on. Only one should be
    A2                  Both Former Sensors Switch Are On (V1-V2)
                                                                               activated at a time. This occurs when the reed switches are not adjusted properly, please refer to
                                                                               POINTS E & F for readjustment.

                                                                               Check the sensors on the tobacco former cylinder (C1-2). This is the cylinder that cuts and forms the
                                                                               tobacco. The sensor closest to the cutter blade should turn OFF when the cylinder retracts (while
    A3        Tobacco Former Did Not Move Away From Extracted Position (V2)
                                                                               opening up the tobacco former… VALVE OFF). If this is not the case please refer to the troubleshooting
                                                                               procedure before this alarm list.

                                                                               Check the sensors on the tobacco former cylinder (C1-2). This is the cylinder that cuts and forms the
                                                                               tobacco. The sensor closest to the cutter blade should be lit up when the cylinder extracts (while
    A4              Tobacco Former Is Not In The Extracted Position (V2)
                                                                               forming tobacco… VALVE ON). If this is not the case please refer to the troubleshooting procedure
                                                                               before this alarm list.

                                                                               Check the sensors on the tobacco former cylinder (C1-2). This is the cylinder that cuts and forms the
                                                                               tobacco. The sensor furthest away from the cutter blade should turn OFF when the cylinder extracts
    A5       Tobacco Former Did Not Move Away From The Safe Position (V1-V2)
                                                                               (while forming tobacco… VALVE ON). If this is not the case please refer to the troubleshooting
                                                                               procedure before this alarm list.

                                                                               Check the sensors on the tobacco former cylinder (C1-2). This is the cylinder that cuts and forms the
                                                                               tobacco. The sensor furthest away from the cutter blade should be lit up when the cylinder retracts
    A6               Tobacco Former Is Not In The Safe Position (V1-V2)
                                                                               (while opening up the tobacco former.. VALVE OFF). If this is not the case please refer to the
                                                                               troubleshooting procedure before this alarm list.

                                                                               Check the sensors on the tube loading cylinder (C3). This is the cylinder that pushes the tubes out of
                                                                               the cassette and onto the transfer tubes. The sensor closest to the cassette should turn OFF when the
    A7           Tube Loading Did Not Move Away From Safe Position (V3)
                                                                               cylinder extracts (while loading a tube… VALVE ON). If this is not the case please refer to the
                                                                               troubleshooting procedure before this alarm list.

                                                                               Check the sensors on the tube loading cylinder (C3). This is the cylinder that pushes the tubes out of
                                                                               the cassette and onto the transfer tubes. The sensor closest to the cabinet wall should be lit up when
    A8                  Tube Loading Is In The Not Safe Position (V3)
                                                                               the cylinder is retracted (not in use… VALVE OFF). If this is not the case please refer to the
                                                                               troubleshooting procedure before this alarm list.




                                                                                                                                                                              PG. 15
          Alarm List and Solutions (Cont.)
Alarm Code            Alarm Description                                   Alarm Solution
                                                                          Check the sensor on the tube eject cylinder (C4). This is the cylinder that pushes the finished cigarettes
    A9        Tube Eject Did Not Move Away From The Safe Position (V4)    outside of the machine. The sensor should turn OFF while extracted (pushing the cigarette out…
                                                                          VALVE ON). If this is not the case please refer to the troubleshooting procedure before this alarm list.


                                                                          Check the sensor on the tube eject cylinder (C4). This is the cylinder that pushes the finished cigarettes
    A10               Tube Eject Is Not In The Safe Position (V4)         outside of the machine. The sensor should be lit up while retracted (not in use… VALVE OFF). If this is
                                                                          not the case please refer to the troubleshooting procedure before this alarm list.


                                                                          Check the sensor on the tube reject cylinder (C5). This is the cylinder that flushes the bad cigarettes.
    A11      Tube Reject Did Not Move Away From The Safe Position (V5)    The sensor should turn OFF while extracted (flushing the cigarette… VALVE ON). If this is not the case
                                                                          please refer to the troubleshooting procedure before this alarm list.


                                                                          Check the sensor on the tube reject cylinder (C5). This is the cylinder that flushes the bad cigarettes.
    A12              Tube Reject Is Not In The Safe Position (V5)         The sensor should be lit up while retracted (not in use… VALVE OFF). If this is not the case please refer
                                                                          to the troubleshooting procedure before this alarm list.


                                                                          Check the sensors on the indexer cylinder. This is the cylinder that indexes the drum. The sensor
    A13      Indexer Did Not Move Away From The Endstroke Position (V7)   closest to the machine operator should turn OFF when the cylinder retracts (while Indexing… VALVE
                                                                          OFF). If this is not the case please refer to the troubleshooting procedure before this alarm list.


                                                                          Check the sensors on the indexer cylinder. This is the cylinder indexes the drum. The sensor closest to
    A14              Indexer Is Not At The Endstroke Position (V7)        the machine operator should be lit up when the cylinder extracts (while getting ready to index…
                                                                          VALVE ON). If this is not the case please refer to the troubleshooting procedure before this alarm list.


                                                                          Check the sensors on the indexer cylinder. This is the cylinder indexes the drum. The sensor furthest
                                                                          away from the machine operator should turn OFF when the cylinder extracts (while getting ready to
    A15      Indexer Did Not Move Away From The Returned Position (V7)
                                                                          index… VALVE ON). If this is not the case please refer to the troubleshooting procedure before this
                                                                          alarm list.


                                                                          Check the sensors on the indexer cylinder. This is the cylinder indexes the drum. The sensor furthest
    A16              Indexer Is Not At The Returned Position (V7)         away from the machine operator should be lit up when the cylinder retracts (while Indexing… VALVE
                                                                          OFF). If this is not the case please refer to the troubleshooting procedure before this alarm list.




                                                                                                                                                                           PG. 16
          Alarm List and Solutions (Cont.)
Alarm Code            Alarm Description                                    Alarm Solution
                                                                           Check the sensors on the indexer cylinder. This is the cylinder indexes the drum. This alarm means
                                                                           that the endstroke (extracted) and the returned (retracted) sensors are both on. Only one should be
    A17                 Both Indexer Reed Switchs are On (V7)
                                                                           activated at a time. This occurs when the reed switches are not properly adjusted. Please refer to
                                                                           POINTS E & F for the readjustment process.

                                                                           Check the sensors on the injector cylinder (C8). This is the cylinder that injects the tobacco into the
                                                                           steel transfer tubes. The sensor closest to the indexer should turn OFF when the cylinder retracts
    A18      Injector Did Not Move Away From The Extracted Position (V8)
                                                                           (getting out of the tube… VALVE OFF). If this is not the case please refer to the troubleshooting
                                                                           procedure before this alarm list.

                                                                           The usual cause for this alarm is that tobacco is jammed so tightly in the former that the injector
                                                                           cannot push it through. Please clean the tobacco out of the former. If this happens often you may
                                                                           need to reduce the tobacco compression value. Also, the tobacco may be too humid. Check the
    A19              Injector Is Not In The Extracted Position (V8)        sensors on the injector cylinder (C8). This is the cylinder that injects the tobacco into the steel transfer
                                                                           tubes. The sensor closest to the indexer should be lit up when the cylinder extracts (while going in the
                                                                           tube… VALVE ON). If this is not the case please refer to the troubleshooting procedure before this
                                                                           alarm list.

                                                                           Check the sensors on the injector cylinder (C8). This is the cylinder that injects the tobacco into the
                                                                           steel transfer tubes. The sensor furthest away from the indexer (closest to the cabinet wall) should
    A20        Injector Did Not Move Away From The Safe Position (V8)
                                                                           turn OFF when the cylinder extracts (while going in the tube… VALVE ON). If this is not the case please
                                                                           refer to the troubleshooting procedure before this alarm list.

                                                                           Check the sensors on the injector cylinder (C8). This is the cylinder that injects the tobacco into the
                                                                           steel transfer tubes. The sensor furthest away from the indexer (closest to the cabinet wall) should be
    A21                Injector Is Not In The Safe Position (V8)
                                                                           lit up when the cylinder retracts (getting out of the tube… VALVE OFF). If this is not the case please
                                                                           refer to the troubleshooting procedure before this alarm list.

                                                                           Check the sensors on the injector cylinder (C8). This is the cylinder that injects the tobacco into the
                                                                           steel transfer tubes. This alarm means that the SAFE and the OUT sensors are both on. Only one
    A22                Both Injector Reed Switchs Are On (V8)
                                                                           should be activated at a time. This occurs when the reed switches are not properly adjusted. Please
                                                                           refer to POINTS E & F for the readjustment process.

                                                                           Check to see if you turned the air pressure valve back on after Daily Maintenance. Check both the red
                                                                           valve in the top left of the machine and the white valve on the bottom right of the machine. If the
                                                                           problem persists, the compressor may have shut down due to overheating. If this is the case it will
                                                                           need to be manually reset. There is a reset button on the back of the compressor itself. Also verify
    A23                            Low Air Pressure
                                                                           that you still have power in the compressor plug circuit. You may want to plug it in to a different
                                                                           circuit or check to see if a breaker was tripped. If none of this works you may have an air leak in one of
                                                                           your hoses. Attempt to find the leak by spraying soapy water onto hoses and fittings. (NOTE: UNPLUG
                                                                           THE MACHINE BEFORE OPENING ANY ELECTRICAL COVER)



                                                                                                                                                                              PG. 17
          Alarm List and Solutions (Cont.)
Alarm Code     Alarm Description                               Alarm Solution
                                                               Check to make sure that tobacco was added at the beginning of the production process. If the tobacco
                                                               was too moist there is a possibility that it jammed before reaching the packing station. Look inside of
                                                               the machine from the back of the cabinet. Above the conveyor assembly (two vertical belts) there
                                                               should be a clear plastic piece with a handle on it. Check to see if tobacco is jammed behind this piece.
    A24                 No Tobacco Was Added
                                                               If it is not jammed, try passing some tobacco down into the belts to see if the sensors respond. If the
                                                               sensors do not respond then they are likely to be defective or have a bad connection in a junction box
                                                               or main electrical panel. Replace the sensors if required. (NOTE: UNPLUG THE MACHINE BEFORE
                                                               OPENING ANY ELECTRICAL COVER)

                                                               Tobacco may be jammed in the chute where the tobacco level sensors are located. These are the two
                                                               black sensors that you clean as part of the Daily Maintenance. Access them as you would normally,
                                                               but stick your hand into the chute to check for a large clump of tobacco that you can knock loose. If
                                                               there is no tobacco or other substance blocking this passage then you may need to clean your sensors.
    A25           Tobacco Level Sensor Is Always Full
                                                               It's possible that dust or tobacco could be causing the sensors to activate. Clean them off with a Q-tip.
                                                               If the sensors do not respond then they are likely to be defective or have a bad connection in a
                                                               junction box or main electrical panel. Replace the sensors if required. (NOTE: UNPLUG THE MACHINE
                                                               BEFORE OPENING ANY ELECTRICAL COVER)

                                                               This is caused by not having a tube load on to the steel transfer tubes 4 times in a row. It is likely that
                                                               the tubes are jammed on the loading station or inside the cassette. Make sure the tube sensor detects
                                                               tubes when they are placed under it. This sensor is located behind where the cassette is placed. If the
    A26            Too Many Missing Tubes In A Row
                                                               sensor does not respond (light up) then it is likely to be defective or have a bad connection in a
                                                               junction box or main electrical panel. Replace the sensor if required. (NOTE: UNPLUG THE MACHINE
                                                               BEFORE OPENING ANY ELECTRICAL COVER)

                                                               This is caused when the machine detects a tube at the reject station 3 times in a row. The cause could
                                                               be that there was not enough tobacco injected into the tubes or that they were not loaded onto the
                                                               steel transfer tubes properly. Also if the reject sensor is not adjusted properly (too close to the
                                                               indexer), it will detect the indexer itself. Another possibility is that the tobacco jammed in the
    A27           Too Many Unfilled Tubes In A Row
                                                               conveyor assembly (two vertical belts), causing the tobacco to pack between the belts before it is
                                                               injected. If the sensor does not respond then it is likely to be defective or have a bad connection in a
                                                               junction box or main electrical panel. Replace the sensor if required. (NOTE: UNPLUG THE MACHINE
                                                               BEFORE OPENING ANY ELECTRICAL COVER)

                                                               Check to make sure that the cassette was placed into the machine correctly. Make sure it is on the
                                                               rails and pushed in completely. If the cassette is loaded correctly and the alarm still appears then the
    A28      Cassette Is Not Present, Please Insert Cassette
                                                               sensor for the cassette may need readjusted. This sensor is located right above the back of the
                                                               cassette. This may need raised or lowered so that it can make better contact with the cassette itself.


                                                               Check to make sure that the cassette is not still loaded in the machine. If it is, please take it out and hit
    A29                 Cassette Is Still Present!             “Reset, Try Again”. If it is already out check to make sure nothing is pressing into the sensor near the
                                                               back of the cassette station causing it to activate.


                                                                                                                                                                   PG. 18
          Alarm List and Solutions (Cont.)
Alarm Code               Alarm Description                                       Alarm Solution
                                                                                 This is caused by the down switch being constantly activated or the motor not turning at all while
                                                                                 trying to move the cassette up. Check the coupling on the motor on the front left of the machine.
                                                                                 Make sure it is tightened properly. Also, the down switch may need to be adjust to a lower position. If
    A30            Cassette Did Not Move Away From The Down Switch
                                                                                 the sensor does not respond, then the sensor is likely to be defective or have a bad connection in the
                                                                                 junction box or in the main electrical panel. Replace the sensor if required. (NOTE: UNPLUG THE
                                                                                 MACHINE BEFORE OPENING ANY ELECTRICAL COVER)

                                                                                 This is caused by the up switch being too far from the cam or that the motor does not turn at all while
                                                                                 trying to raise the cassette. If the sensor does not respond, then the sensor is likely to be defective or
    A31                  Cassette Did Not Register The Up Switch
                                                                                 have a bad connection in the junction box or in the main electrical panel. Replace the sensor if
                                                                                 required. (NOTE: UNPLUG THE MACHINE BEFORE OPENING ANY ELECTRICAL COVER)

                                                                                 This is caused by the up switch being too far from the cam or that the motor does not turn at all while
             Error, Cassette Returned To The Down Position Again (Did Not Find   trying to raise the cassette. If the sensor does not respond, then the sensor is likely to be defective or
    A32
                                            UP)                                  have a bad connection in the junction box or in the main electrical panel. Replace the sensor if
                                                                                 required. (NOTE: UNPLUG THE MACHINE BEFORE OPENING ANY ELECTRICAL COVER)

                                                                                 This is caused by the up switch being constantly activated or the motor not turning at all while trying
                                                                                 to lower the cassette. Check the coupling on the motor on the front left of the machine. Make sure it
                                                                                 is tightened properly. Also, the up switch may need to be adjusted to a higher position. If the sensor
    A33              Cassette Did Not Move Away From The Up Switch
                                                                                 does not respond, then the sensor is likely to be defective or have a bad connection in the junction
                                                                                 box or in the main electrical panel. Replace the sensor if required. (NOTE: UNPLUG THE MACHINE
                                                                                 BEFORE OPENING ANY ELECTRICAL COVER)

                                                                                 This is caused by the down switch being too far from the cam or that the motor does not turn at all
                                                                                 while trying to raise the cassette. If the sensor does not respond, then the sensor is likely to be
    A34                 Cassette Did Not Register The Down Switch
                                                                                 defective or have a bad connection in the junction box or in the main electrical panel. Replace the
                                                                                 sensor if required. (NOTE: UNPLUG THE MACHINE BEFORE OPENING ANY ELECTRICAL COVER)

                                                                                 This is caused by the down switch being too far from the cam or that the motor does not turn at all
              Error, Cassette Returned To The Up Position Again (Did Not Find    while trying to raise the cassette. If the sensor does not respond, then the sensor is likely to be
    A35
                                          Down)                                  defective or have a bad connection in the junction box or in the main electrical panel. Replace the
                                                                                 sensor if required. (NOTE: UNPLUG THE MACHINE BEFORE OPENING ANY ELECTRICAL COVER)


                                                                                 This is caused by powering up the machine with neither the up or down switch activated. Simply press
    A36               Cassette Position Lost, Need To Register Switch
                                                                                 reset.



                                                                                 This is caused when both the up and the down switches are not being activated by the cam. Readjust
    A37                   Failure To Register Up Or Down Switch
                                                                                 the switches.



                                                                                                                                                                                   PG. 19
          Alarm List and Solutions (Cont.)
Alarm Code           Alarm Description                                   Alarm Solution
                                                                         This is caused when the cassette was left in the machine by a previous customer and then a new
    A38              Cassette Must Be Removed, Clean Tubes
                                                                         customer presses the “Added Tobacco” button. Simply remove the cassette and the loose tubes.



                                                                         This is caused when the up and the down switches are activated by the cam at the same time. Only
    A39      Cassette Up And Down Switchs Activated At The Same Time     one switch should be activated at a time. Readjust the switches by raising the up switch and lowering
                                                                         the down switch.

                                                                         You will need to view the inside of the machine from the front door to troubleshoot this. Once the
                                                                         door is opened locate the tube detector sensor. You clean this sensor as part of your daily
                                                                         maintenance. It is right above the drum with the six steel transfer tubes. Whenever this sensor detects
                                                                         a tube, or something underneath of it, it lights up. Check to see if there are any broken cigarette tubes
                                                                         stuck on any of the transfer tubes. If there is remove them VERY carefully. What is happening is the
                                                                         sensor is picking up the broken part of the white tube. If there are none then clean the sensor. It may
    A40      Tube Detector At Injector Is Always On, Check Broken Tube   be picking up dust or tobacco remnants. If the problem persists after this you may need to readjust
                                                                         the sensor. It will need to be brought further away from the transfer tubes if it is constantly lit. This is
                                                                         because it's close enough to “sense” the metal and light up. You can do this by loosening the bottom
                                                                         nut, pulling the sensor up, and then tightening the top nut. If it doesn't light up even when a white
                                                                         cigarette tube is loaded on a transfer tube then you will need to move it closer. You can do this by
                                                                         loosening the top nut, pulling the sensor up, and then tightening the bottom nut. Be sure to tighten
                                                                         the sensor in place properly when finished or it will vibrate loose.

                                                                         Check to make sure that this cassette door is closed. This is the small black door on the front of the
                                                                         machine. If it is closed check to make sure the magnet sensors are still present and attached correctly
    A41               Cassette Door Not Closed, Please Close             without a large gap between them. These are small rectangular white boxes located where the
                                                                         cassette door closes. If there is too large of a gap between the two magnets they won't read correctly
                                                                         and will need moved closer together.

                                                                         Please add more tobacco into the chute. If enough tobacco was added and this still occurs there may
                                                                         be a tobacco jam. Look inside the machine from the back of the cabinet. Above the conveyor assembly
    A42                          Out Of Tobacco                          (two belts) there should be a clear plastic piece with a handle on it. Check to see if tobacco is jammed
                                                                         behind this piece. If this is the case, the tobacco used may have been too moist. You can try pushing
                                                                         the tobacco down with your hand, but if it is too moist it may jam up again in the compression belts.

                                                                         Check the sensors on the reject cylinder (C5). This is the cylinder that rejects the bad cigarette. The
                                                                         sensor closest to the indexer (rod side) should be lit up when the cylinder extracts (while going in the
    A43             Tube Reject Is Not In The Out Position (V5)
                                                                         tube… VALVE ON). If this is not the case please refer to the troubleshooting procedure before this
                                                                         alarm list.




                                                                                                                                                                            PG. 20
          Alarm List and Solutions (Cont.)
Alarm Code                Alarm Description                                           Alarm Solution
                                                                                      Check the sensors on the reject cylinder (C5). This is the cylinder that rejects the bad cigarette. The
                                                                                      sensor closest to the indexer (rod side) should turn OFF when the cylinder retracts (getting out of the
    A44             Tube Reject Did Not Move From The Out Position (V5)
                                                                                      tube… VALVE OFF). If this is not the case please refer to the troubleshooting procedure before this
                                                                                      alarm list.

                                                                                      Check the sensors on the reject cylinder (C5). This is the cylinder that rejects the bad cigarette. This
                                                                                      alarm means that the SAFE (retracted) and the OUT (extracted) sensors are both on. Only one should
    A45                     Both Reject Reed Switchs Are On (V5)
                                                                                      be activated at a time. This occurs when the reed switches are not properly adjusted. Please refer to
                                                                                      POINTS E & F for readjustment.

                                                                                      This alarm can be caused by a faulty power supply due to a “shorted” motor. If you reset the alarm
                                                                                      and it reappears then the power supply is either faulty or a short is present. If the alarm disappears
                                                                                      then the 12V DC circuit is OK. The probable cause is a “shorted” motor or the motor wiring. Go to the
                                                                                      IO Screen page on the HMI touch screen and notice the counters on the right. Any time there is a short
                                                                                      these counters will increment. This is a good tool to see which motor is causing the problem. Another
    A46                       12V DC Power Supply Is Out (PS2)
                                                                                      way is to unplug one motor at a time and restart the machine. If the alarm goes away then that is the
                                                                                      motor causing the problem. (BE CAREFUL WITH THE CONNECTIONS - THEY ARE FRAGILE) . Another
                                                                                      thing that can cause this is if the tobacco compression belts are packed too solid with tobacco. This
                                                                                      causes the motor to not turn and causes alarm A46. You can unlatch the conveyor assembly (two
                                                                                      vertical compression belts) and try to unjam it.

                                                                                      When the “ADDED TOBACCO” button was pressed there was a loose tube present in the cassette
                                                                                      receptacle. Simply remove any tube present. If there isn't a tube, the tube sensor may be reading the
    A47               Remove Tube Before Inserting The Cassette (Ph84)                metal of the loading station. In this case the sensor will need to be readjusted, most probably moved
                                                                                      up (or away from the metal). If you move it too far out then it won't be able to detect any tubes and
                                                                                      will need readjusted closer.

                                                                                      This alarms happens when the indexer's back reed switch activates after the tubes are detected at the
    A48           Readjust RS7B, Indexer Back Reedswitch. Signal Too Soon             injection station. Readjust the sensor so there is a 3/8” gap between the black indexer side and the
                                                                                      reed switch.


                                                                                      This alarm happens when the reject cylinder comes back to the safe (retracted) position and still is a
                                                                                      detects a rejected tube. A possible cause is that a tube is still present. If this is the case simply remove
    A49      Reject Still Present At The Reject Station, Try Again or Remove Reject
                                                                                      the tube. Another possibility is that the sensor is adjusted to close to the indexer's drum, which is
                                                                                      causing it to read the drum instead of tubes. Readjust the sensor.

                                                                                      Check the sensors on the tube former cylinder (C9). This is the cylinder that pre-forms the tubes
                                                                                      before they are inserted over the steel transfer tubes. This alarm means that the SAFE (retracted) and
    A50               A50-Both Tube Former Sensors Switch Are On (V9)
                                                                                      the OUT (extracted) sensors are both on. Only should be activated at a time. This occurs when the
                                                                                      reed switches are not properly adjusted. Please refer to POINTS E & F for readjustment.



                                                                                                                                                                                          PG. 21
             Alarm List and Solutions (Cont.)
Alarm Code                Alarm Description                                     Alarm Solution
                                                                                Check the sensors on the tube former cylinder (C9). This is the cylinder that pre-forms the tubes
                                                                                before they are inserted over the steel transfer tubes. The sensor closest to the indexer should turn
    A51       A51-Tube Former Did Not Moved Away From Extracted Position (V9)
                                                                                OFF when the cylinder retracts (getting out of the tube… VALVE OFF). If this is not the case please refer
                                                                                to the troubleshooting procedure before this alarm list.

                                                                                Check the sensors on the tube former cylinder (C9). This is the cylinder that pre-forms the tubes
                                                                                before they are inserted over the steel transfer tubes. The sensor closest to the indexer should be lit
    A52             A52-Tube Former Is Not At The Extracted Position (V9)
                                                                                up when the cylinder extracts (while going in the tube… VALVE ON). If this is not the case please refer
                                                                                to the troubleshooting procedure before this alarm list.

                                                                                Check the sensors on the tube former cylinder (C9). This is the cylinder that pre-forms the tubes
                                                                                before they are inserted over the steel transfer tubes. The sensor furthest away from the indexer
    A53       A53-Tube Former Did Not Moved Away From The Safe Position (V9)
                                                                                should turn OFF when the cylinder extracts (while going in the tube… VALVE ON). If this is not the case
                                                                                please refer to the troubleshooting procedure before this alarm list.

                                                                                Check the sensors on the tube former cylinder (C9). This is the cylinder that pre-forms the tubes
                                                                                before they are inserted over the steel transfer tubes. The sensor furthest away from the indexer
    A54               A54-Tube Former Is Not At The Safe Position (V9)
                                                                                should be lit up when the cylinder retracts (getting out of the tube… VALVE OFF). If this is not the case
                                                                                please refer to the troubleshooting procedure before this alarm list.

                                                                                Check the sensors on the tube former cylinder (C9). This is the cylinder that pre-forms the tubes
                                                                                before they are inserted over the steel transfer tubes. The sensor closest to the indexer should turn
    A51       A51-Tube Former Did Not Moved Away From Extracted Position (V9)
                                                                                OFF when the cylinder retracts (getting out of the tube… VALVE OFF). If this is not the case please refer
                                                                                to the troubleshooting procedure before this alarm list.

                                                                                Check the sensors on the tube former cylinder (C9). This is the cylinder that pre-forms the tubes
                                                                                before they are inserted over the steel transfer tubes. The sensor closest to the indexer should be lit
    A52             A52-Tube Former Is Not At The Extracted Position (V9)
                                                                                up when the cylinder extracts (while going in the tube… VALVE ON). If this is not the case please refer
                                                                                to the troubleshooting procedure before this alarm list.

                                                                                Check the sensors on the tube former cylinder (C9). This is the cylinder that pre-forms the tubes
                                                                                before they are inserted over the steel transfer tubes. The sensor furthest away from the indexer
    A53       A53-Tube Former Did Not Moved Away From The Safe Position (V9)
                                                                                should turn OFF when the cylinder extracts (while going in the tube… VALVE ON). If this is not the case
                                                                                please refer to the troubleshooting procedure before this alarm list.



   A55-A62                              Placeholder                             Placeholder for any future alarm additions.




                                                                                                                                                                                 PG. 22
          Alarm List and Solutions (Cont.)
Alarm Code    Alarm Description                Alarm Solution
    A63         Machine Has No Serial Number   The program has lost part of it's memory. (CALL RYO)




    A64            Data Not Loaded In PLC      The program has lost part of it's memory. (CALL RYO)




    A65             PLC Not In Run Mode        The program has stopped, a test need to be done. (CALL RYO)




    A66               PLC Module Error         There is a PLC Error. (CALL RYO)




    A67           Touch Screen Battery Low     The touch screen needs a new battery. (CALL RYO)




                                                                                                             PG. 23
                             Glossary of Terms
   Term              Image                                                          Description


                                The Drum Assembly is the portion of the machine which controls the paper tube position as well as cuts the tobacco prior to
                                injecting. A top down view from the back of the cabinet will show the drum on the right side of the assembly. The Indexer
 Drum Assembly
                                Cylinder will be located on the left, which controls the drums rotation. There will be a large cylinder on the side closest to you,
                                this is Cylinder 1-2 and controls the blade that cuts the tobacco. Above the Drum Assembly is the Dozing Conveyor Assembly.




                                The Dozing Conveyor Assembly is the portion of the machine that compresses the tobacco to the desired value. Tobacco is fed
Dozing Conveyor
                                into the black chute at the top and moves downwards with the help of the two vertical belts placed on either side. There are
   Assembly
                                two sensors on this assembly which should be cleaned daily, as well as two gears which should be greased regularly.




                                The Injection Assembly is the portion of the machine that injects paper tubes with tobacco as well as ejects and rejects them
Injection Assembly              from the machine. It is comprised of four different cylinders with rods attached to them that pass through the Drum Assembly.
                                This assembly also has an adjustment crank on it than can adjust the depth the tobacco is pushed into each paper tube.




                                                                                                                                                            PG. 24
                               Glossary of Terms
    Term               Image                                                           Description


                                  The Tube Loading Assembly is the portion of the machine that helps all of the paper tubes out of their package and readies them
   Tube Loading
                                  to be loaded onto transfer tubes. It’s comprised of the entire cassette area, as well as the base plate that the whole machine is
     Assembly
                                  attached to.




                                  The Hopper Assembly is the portion of the machine which the tobacco is loaded into. It has a large chamber to store the tobacco.
 Hopper Assembly                  A horizontal belt then moves the tobacco into a tumbler that helps break apart all large clumps of tobacco. The tobacco then falls
                                  down into the Conveyor Assembly.




                                  The Air Preparation Unit is the portion of the machine that is located on the side wall of the cabinet. All of the air from the
                                  compressors pass through this unit, which is comprised of water filters and oil separators. This unit also has a regulator on it that
Air Preparation Unit
                                  allows you to change the air pressure applied to the entire machine as well as a knob that releases air pressure from the machine
                                  so that all pneumatic cylinders are easily movable.




                                                                                                                                                               PG. 25
                              Glossary of Terms
Term             Image                                                                       Description
                                        Batches are a type of “credit” system that are used with the machine. Each batch is equal to exactly 200 good cigarettes. As your
                                        customers roll cartons of cigarettes your total remaining batch count will decrease. As this count decreases you will need to
 Batch           Not Applicable
                                        order more batches from RYO Machines. Only good cigarettes are counted and deducted from your batch total, we will never
                                        charge you for cigarettes that the machine rejects into the vacuum bag.




                                        There are three different belts that appear in the machine to help tobacco progress through it. A horizontal belt appears in the
  Belt                                  Hopper Assembly and two vertical belts appear in the Conveyor Assembly. It’s important to be extremely careful if you ever try
                                        to adjust these belts. If you adjust them too tightly you may put too much pressure on a bearing which would cause it to break.




                                        A blade appears in the Drum Assembly that cuts the tobacco before it is injected into each paper tube. It is controlled by the
 Blade     Refer to the Drum Assembly   Tobacco Forming cylinder and is situated directly beneath the Conveyor Assembly. This blade is made out of high carbon D2
                                        steel and will last a lifetime as long as it is only used to cut tobacco. This blade is cleaned daily as part of your maintenance.




                                        The main function of the Cassette is to hold the box of paper tubes that are loaded into the machine. While in the machine it is
Cassette                                raised and lowered to different heights to help the paper tubes roll out of their container. The machine will not roll cigarettes
                                        unless the Cassette is present. Each machine ships with two Cassettes. Extra Cassettes are available for order.




                                                                                                                                                                     PG. 26
                            Glossary of Terms
Term          Image                                                                    Description

                                  A Crank is attached to the rear of the Injection Assembly. You can reach this crank from the small door on the side of the cabinet.
 Crank                            This crank controls the depth to which tobacco is pushed into the paper tubes. Turning it clockwise causes tobacco to be pushed
                                  deeper while turning it counterclockwise causes it to do the opposite.




                                  The Curb a removable piece of the cabinet located near the floor. It’s a black rim that surrounds the cabinet and acts as a shelf for
 Curb      Refer to the Cabinet
                                  containers to receive tobacco and cigarettes.




                                  Numerous cylinders appear throughout the machine, each with a different function that helps the machine operate. These
Cylinder
                                  cylinders are all controlled by air pressure that extract and retract the attached rods.




                                  The Drum appears in the Drum Assembly. It contains size transfer tubes that paper tubes are loaded onto. It rotates during
 Drum
                                  production to move each paper tube to a different station. It’s rotation is controller by the Indexer cylinder.




                                                                                                                                                              PG. 27
                       Glossary of Terms
Term           Image                                                           Description


                          There are numerous fittings that appear throughout the machine. A example picture is to the left. They come in many different
   Fitting
                          shapes and sizes. The main function of a fitting is to allow a place for tubing to connect to.




                          The Flex Tip is located on the end of the rod attached to the Tube Forming Cylinder. It passes through the Drum Assembly. It’s
  Flex Tip                main function is to help misshapen paper tubes load onto the transfer tubes more easily, thus decreasing the amount of rejected
                          cigarettes. It is recommended to be replaced every 1200 batches.




                          A Flow Control is another type of fitting. These fittings are more than just a connector for tubing, though. Each one has a dial on
Flow Control              the top of it. This dial controls the amount of airflow allowed to pass through it, which in turn affects the speed at which cylinders
                          activate. They are located on a metal bracket in the back of the cabinet.




                                                                                                                                                       PG. 28
                       Glossary of Terms
Term           Image                                                           Description


                          There are numerous gears that appear throughout the machine. A example picture is to the left. They come in many different
   Gear                   shapes and sizes. Each one of these gears should have white lithium grease applied to is occasionally to keep it in great working
                          condition.




                          There are three black Junction Boxes that appear throughout the machine. Each Junction Box contains electrical wiring junctions.
Junction Box
                          There is also a power plug in the back of each box.




                          There are four motors that appear throughout the machine. Each one has a different function and they are not interchangeable.
  Motor                   There are two electrical contacts on each motor. It is important to be very gentle if these electrical wires are ever removed as the
                          contacts are very fragile. If you accidentally break a contact you will need to replace the entire motor.




                                                                                                                                                      PG. 29
                                  Glossary of Terms
      Term                Image                                                          Description

                                     Two regulators appear through the machine. One of the is built into the Air Preparation Unit and it controls the air pressure to the
       Regulator                     entire machine. The other is located near all of the flow controls and it controls the air pressure solely to the Indexer Cylinder.
                                     This cylinder operates at a lower air pressure than the rest of the machine.




                                     Sensors (also called reed switches) appear throughout the machine multiple times. These sensors come in different shapes and
        Sensor                       sizes (a few examples appear to the left), but all have the same functions. Each sensor is in charge of detecting something,
                                     whether it is the position of a cylinder or location of paper tubes or tobacco.




                                     There are six Transfer Tubes located in the Drum Assembly. Paper tubes are loaded onto them and they are in turn injected with
     Transfer Tube
                                     tobacco.




                                     The Valve Manifold Assembly is the control panel for all of the pneumatics. It’s located in the back of the machine. It’s comprised
Valve Manifold Assembly              of 9 pneumatic valves that each actuate a different cylinder. These valves all have manual activation buttons for each of the
                                     cylinders, which are very useful for troubleshooting.




                                                                                                                                                                PG. 30
   FURTHER DOCUMENTATION,
TROUBLESHOOTING AND WARRANTY
         INFORMATION
• Further Documentation
  Future updates to both this reference manual and the training manual will be available on our website
  located at www.ryofillingstation.com.


• Troubleshooting
  All troubleshooting should be done over the phone with an RYO Machines employee. Please call us at
  (330) 646-1118.


• Warranty Information
  All warranty terms will be decided and agreed upon at the time of purchase. Please see your personal
  records for more detailed information.




                                                                                                          PG. 31
     RYO MACHINES
Model 25 Hot Rod Filling Station

          LS HMI Training




                            By: M.A.D. Concept Inc.
                    About Screen (Contacts)




       CONTACTS




                                                                  PRESS HERE TO EXIT
PLC & HMI Version




            POWER LED, WILL    AMOUNT OF AMOUNT OF CIGARETTES
          ALWAYS BE ON WHEN     BATCHES   REMAINING (PURCHASED)
             THE MACHINE IS    REMAINING
           RECEIVING POWER    (PURCHASED)




                                                                                   PG. 32
                    Language Screen
                 HIDDEN BUTTON TO ACCES SETUP SCREEN, PRESS 3 TIMES
              WITHIN 2 SECONDS AND THIS WILL BRING YOU TO THE PASSWORD
                                       SCREEN




                                                   PRESS HERE TO EXIT
  POWER LED, WILL
ALWAYS BE ON WHEN             PRESS HERE TO
   THE MACHINE IS           CHOOSE A LANGUAGE
 RECEIVING POWER

                    LANGUAGE WILL REVERT BACK TO ENGLISH AFTER EACH
                                      CUSTOMER

                                                                         PG. 33
       Main Screen, Load Tobacco




                                                                                 PRESS HERE FOR
                                                                                 CONTACTS




                                                                                     PRESS HERE TO
CLOCK OR                                                                            CHANGE LANGUAGE
 ALARM
MESSAGES




                                        PRESS HERE AFTER
     POWER LED, WILL
                                       ADDING THE TOBACCO
   ALWAYS BE ON WHEN
      THE MACHINE IS
    RECEIVING POWER

            THE HMI SCREEN BACKLIGHT WILL TURN ON AT 6.00 AM AND TURN OFF AT 6:59 PM,
           PRESS ANYWHERE ON THE SCREEN TO TURN THE LIGHT BACK ON. IF BETWEEN 7PM
             AND 6AM, EVERY 15 MINUTES THE SCREEN WILL TURN OFF, JUST PRESS AGAIN
                                                                                                  PG. 34
                  Tube Loading Screen




WILL FLASH IF
NO CASSETTE
 IS PRESENT



CLOCK OR
 ALARM
MESSAGES




                         PRESS HERE                        PRESS HERE TO
      POWER LED, WILL                           Cassette Is Not Present FLUSH THE
                        AFTER ADDING                   CANCEL AND
    ALWAYS BE ON WHEN
                          THE TUBES                           TOBACCO
       THE MACHINE IS
                                        PRESS HERE TO
     RECEIVING POWER
                                       CHANGE LANGUAGE




                                                                                    PG. 35
                          Wait Screen
                         THIS SCREEN WILL CHANGE AUTOMATICALLY




CLOCK OR
 ALARM
MESSAGES




       POWER LED, WILL                              PRESS HERE TO
     ALWAYS BE ON WHEN                           CANCEL AND FLUSH THE
        THE MACHINE IS                                TOBACCO
                                     PRESS HERE TO
      RECEIVING POWER
                                    CHANGE LANGUAGE




                                                                        PG. 36
            Tobacco Recovery Screen




CLOCK OR
 ALARM
MESSAGES




                        PRESS HERE                     PRESS HERE TO
    POWER LED, WILL
                          AFTER                     CANCEL AND FLUSH THE
  ALWAYS BE ON WHEN
                      RECOVERING THE                     TOBACCO
     THE MACHINE IS
                         TOBACCO        PRESS HERE TO
   RECEIVING POWER
                                       CHANGE LANGUAGE




                                                                           PG. 37
                                Run Screen
                          THIS SCREEN WILL CHANGE AUTOMATICALLY




                                                                             PACK MORE TOBACCO INTO CIGARETTE,
                                                                             NOTE 1
                                                                             CURRENT COMPRESSION VALUE
                                                                             PACK LESS TOBACCO INTO CIGARETTE,
                                                                             NOTE 1
                                                                             CIGARETTE RATE PER MINUTE
                                                                             TOTAL TUBES USED COUNTER
                                                                             TOTAL GOOD CIGARETTE COUNTER


CLOCK OR
 ALARM
MESSAGES




                       PRESS HERE TO
     POWER LED, WILL
                         PAUSE THE                     PRESS HERE TO
   ALWAYS BE ON WHEN
                        PRODUCTION                    CHANGE LANGUAGE
      THE MACHINE IS
    RECEIVING POWER                                                     NOTE 1: IF YOU KEEP THIS BUTTON PRESSED
                                                                        DOWN IT WILL CONTINUE TO ADD OR
                                                                        REDUCE THE COMPRESSION VALUE


                                                                                                         PG. 38
                             Stop Screen


                                                                                PACK MORE TOBACCO INTO CIGARETTE,
                                                                                NOTE 1
                                                                                CURRENT COMPRESSION VALUE
                                                                                PACK LESS TOBACCO INTO CIGARETTE,
                                                                                NOTE 1

                                                                                TOTAL TUBES USED COUNTER
                                                                                TOTAL GOOD CIGARETTE MADE
                                                                                COUNTER
CLOCK OR
 ALARM
MESSAGES




                      PRESS HERE TO                 PRESS HERE TO CANCEL AND
    POWER LED, WILL
                         RESUME                    FLUSH THE TOBACCO, MACHINE
  ALWAYS BE ON WHEN
                       PRODUCTION                     MUST BE IN PAUSE MODE
     THE MACHINE IS
                                       PRESS HERE TO
   RECEIVING POWER
                                      CHANGE LANGUAGE                       NOTE 1: IF YOU KEEP THIS BUTTON
                                                                            PRESSED DOWN IT WILL CONTINUE TO ADD
                                                                            OR REDUCE THE COMPRESSION VALUE


                                                                                                            PG. 39
                            Cancel Screen




CLOCK OR
 ALARM
MESSAGES




                         PRESS HERE TO                   PRESS HERE TO GO
       POWER LED, WILL
                             FLUSH                     BACK TO THE PREVIOUS
        ALWAYS BE ON
                                                             SCREEN
          WHEN THE
                                          PRESS HERE TO
         MACHINE IS
                                         CHANGE LANGUAGE
          RECEIVING
           POWER


                                                                              PG. 40
                                 Finished Screen
                                   THIS SCREEN WILL CHANGE AUTOMATICALLY




INDICATES CURRENT
     PROCESS


   COUNT DOWN UNTIL
   BARREL CLEANING IS
       FINISHED




       CLOCK OR
        ALARM
       MESSAGES




                                  TOTAL GOOD                   PRESS HERE TO
             POWER LED, WILL
                               CIGARETTES MADE                CHANGE LANGUAGE
              ALWAYS BE ON
                                   COUNTER
                WHEN THE
               MACHINE IS                    TOTAL TUBE INJECTED
                RECEIVING                         COUNTER
                 POWER


                                                                                PG. 41
                            Clean Screen




CLOCK OR
 ALARM
MESSAGES




                         PRESS HERE                     WILL FLASH IF
     POWER LED, WILL
                       AFTER REMOVING                CASSETTE IS PRESENT
      ALWAYS BE ON
                          TUBES AND
        WHEN THE
                           TOBACCO       PRESS HERE TO
       MACHINE IS
                                        CHANGE LANGUAGE
        RECEIVING                                                          Cassette Is Present
         POWER


                                                                                                 PG. 42
                     Thank you Screen
                         THIS SCREEN WILL CHANGE AUTOMATICALLY




CLOCK OR
 ALARM
MESSAGES




       POWER LED, WILL
        ALWAYS BE ON
          WHEN THE
                                    PRESS HERE TO
         MACHINE IS
                                   CHANGE LANGUAGE
          RECEIVING
           POWER


                                                                 PG. 43
     RYO MACHINES
Model 25 Hot Rod Filling Station

     Owner and Technician Screens




                                    By: M.A.D. Concept Inc.
                    Password Screen
                  THIS SCREEN WILL CHANGE AUTOMATICALLY. IF A VALID
             PASSWORD IS ENTERED YOU CAN ACCESS THE SETUP SCREEN. IF
             NO PASSWORD, OR AN INVALID PASSWORD, IS ENTERED YOU WILL
              BE REDIRECTED TO THE PREVIOUS SCREEN AFTER 10 SECONDS




                                         PRESS HERE TO
  POWER LED, WILL                       CHANGE LANGUAGE
ALWAYS BE ON WHEN
   THE MACHINE IS         PRESS HERE TO ENTER
 RECEIVING POWER           THE PASSWORD, “911”




                                                                        PG. 44
                             Setup Screen                     (for owner & technician)



                                                                                  PRESS HERE TO TURN THE
                                                                                  SINGLE CYCLE ON OR OFF
                                                                                 FOR DEBUGGING PURPOSES.
 PRESS HERE TO RESET                                                               IT WILL ONLY MAKE ONE
       ALARMS                                                                      CIGARETTE AT A TIME IN
                                                                                     SINGLE CYCLE MODE
 THESE 3 LINES ARE THE
 DEFAULT MINIMUM AND
                                                                                 PRESS HERE TO TURN THE
  MAXIMUM TOBACCO
                                                                                 MODEM ON OR OFF NOTE 1
QUANTITY VALUES. PRESS
     TO CHANGE
                                                                                   PRESS HERE TO VIEW
                                                                                    PRODUCTION DATA
PRESS HERE TO RESET THE
 MACHINE TO ITS ORIGINAL
                                                                                   PRESS HERE TO VIEW
 POSITIONS & SEQUENCES
                                                                                  MACHINE SEQUENCER &
                                                                                       PREVENTIVE
                                                                                      MAINTENANCE




                                     PRESS HERE      PRESS HERE     PRESS HERE
                                     TO CHANGE       TO CHANGE       FOR EXTRA
                                      LANGUAGE       TIME / DATE       ITEMS
                          PRESS HERE TO
                                           PRESS HERE TO   PRESS HERE TO
                          RETURN TO THE
                                            VIEW ALARM     ADD CREDITS TO
                         PREVIOUS SCREEN
                                              HISTORY       THE MACHINE
  NOTE 1: THE MODEM WILL                                       NOTE 2
  TURN ON AUTOMATICALLY
   AT MIDNIGHT AND TURN                                            NOTE 2: MACHINE MUST NOT BE IN USE,
  OFF AT 5 AM. THIS BUTTON                                           PLEASE FINISH BATCH OR CANCEL.
  DOES NOT APPEAR ON ALL
  MODELS OF THE MACHINE.                                                                                  PG. 45
                            Production Information
   THESE VALUES WILL RESET
                                                   THESE VALUES ARE NON-
   AT EACH MACHINE RELOAD
                                                   ADJUSTABLE AND WILL BE
        (NEW CREDITS)
                                                   FOR LIFE




                                                                            DISPLAY THE MACHINE’S
                                                                                SERIAL NUMBER



RUN, IDLE AND ALARM TIMES
         IN HOURS
                                                                                  DISPLAYS LOG
                                                                                INFORMATION IN A
                                                                                 GRAPH FORMAT



                                                                             DISPLAYS DETAILED
                                                                             LOG INFORMATION


                POWER LED, WILL    CURRENT     CURRENT CIGARETTES
                 ALWAYS BE ON       BATCH     CREDITED, “AMOUNT OF
                   WHEN THE        CREDITED   GOOD CIGARETTES THAT
                  MACHINE IS                      CAN BE ROLLED
                   RECEIVING                       (PURCHASED)
                    POWER


                                                                                           PG. 46
              Detailed Production Information
THIS IS THE GRAND
TOTAL OF GOOD
TUBES RAN
THROUGH THE
MACHINE.
                                        TAKES YOU BACK TO THE
                                        PREVIOUS SCREEN
THIS IS THE AMOUNT
OF BATCHES                              CYCLES UP 1 PAGE AT A TIME
REMAINING IN THE
MACHINE.                                CYCLES DOWN 1 PAGE AT A TIME

                                        DISPLAYS WHETHER OR NOT A
                                        USB STICK IS PRESENT
THIS IS THE NUMBER
OF GOOD
                                        SAVES ALL OF THE LOGGED
CIGARETTES IN THE
                                        DATA ONTO A USB STICK
CORRESPONDING
BATCH.
                                        DISPLAYS CURRENT SAVE
                                        STATUS
THIS IS THE DATE THAT
THE CORRESPONDING
BATCH WAS RAN ON.


THIS IS THE NUMBER OF
EACH BATCH RAN
THROUGH THE MACHINE.
FOR EXAMPLE: 55 WOULD
BE THE 55TH BATCH THAT
WAS RAN.


                                                          PG. 47
                        Trending Information
TAKES YOU TO THE
LAST BATCH RAN
THROUGH THE
MACHINE




DISPLAYS THE NEXT
100 BATCHES




DISPLAYS THE NEXT
50 BATCHES



DISPLAYS THE PREVIOUS
50 BATCHES




                        THIS IS THE RANGE OF GOOD     DISPLAYS UP TO 100 BATCHES AT A
                        CIGARETTES DISPLAYED ON THE   TIME WITH MARKERS EVERY 10
                        GRAPH.                        BATCHES.
DISPLAYS THE PREVIOUS
100 BATCHES


                                                                                        PG. 48
                Preventive Maintenance



   THESE 11 VALUES
REPRESENT DIFFERENT
                                                                  SET POINT & CURRENT VALUE
 SEQUENCERS OF THE
                                                                      TO ADD OIL INTO THE
MACHINE, THESE VALUES
                                                                     COMPRESSOR. NOTE 1
  ARE FOR TROUBLE
      SHOOTING
                                                                  SET POINT & CURRENT VALUE
                                                                   TO CHANGE THE OIL OF THE
                                                                     COMPRESSOR. NOTE 1




                        RETURN TO SETUP
      POWER LED, WILL
                            SCREEN
       ALWAYS BE ON
         WHEN THE                         NOTE 1: THESE VALUES REFLECT AN AMOUNT
        MACHINE IS                                    OF BATCHES RAN.
         RECEIVING
          POWER


                                                                                   PG. 49
   Add Oil Maintenance Pop Up




                   PRESS HERE AFTER
POWER LED, WILL
                  EXECUTING THE TASK
 ALWAYS BE ON
   WHEN THE
  MACHINE IS
   RECEIVING
    POWER


                                       PG. 50
Change Oil Maintenance Pop Up




                   PRESS HERE AFTER
POWER LED, WILL
                  EXECUTING THE TASK
 ALWAYS BE ON
   WHEN THE
  MACHINE IS
   RECEIVING
    POWER


                                       PG. 51
                             History Screen


PRESS HERE TO RESET
      ALARMS




                                                              LOGGED ALARMS WITH DATE
                                                                  AND TIME STAMP




   RETURN TO SETUP                                             VIEW NEXT OR PREVIOUS
       SCREEN                                                 PAGES IF ALARM HISTORY IS
                                                                MORE THAN ONE PAGE


                                PRESS HERE
                                TO CHANGE
                                 LANGUAGE
           POWER LED, WILL            PRESS HERE TO DELETE
            ALWAYS BE ON              CURRENT HISTORY PAGE.
              WHEN THE                 NOTICE ACTIVE ALARMS
             MACHINE IS                  WILL NOT DELETE
              RECEIVING
               POWER


                                                                               PG. 52
                             Time Screen
                                                     DAYLIGHT SAVING TOGGLE
                              CHANGE VALUES           SWITCH, BACKWARD OR
                                  HERE              FORWARD ONE HOUR. NOTE 1




PRESS HERE TO RESET
      ALARMS

                                                                          DISPLAY THE CURRENT
                                                                         DAYLIGHT SAVING STATUS



                                                                          PRESS HERE TO ACTIVATE /
PRESS HERE TO VALIDATE
                                                                           DEACTIVATE THE SCREEN
   NEW DATE & TIME
                                                                             SAVER (10 MINUTES)

   RETURN TO SETUP
       SCREEN




                              PRESS HERE
                              TO CHANGE
                               LANGUAGE
           POWER LED, WILL
            ALWAYS BE ON
              WHEN THE
             MACHINE IS               NOTE 1: THE DAYLIGHT SAVING IS AUTOMATIC, AT 2AM
              RECEIVING                ON THE FIRST SUNDAY OF NOVEMBER AND SECOND
               POWER                                 SUNDAY OF MARCH


                                                                                           PG. 53
                               Reload Screen
                THIS SCREEN WILL BE DISPLAYED AUTOMATICALLY IF MACHINE IS DEACTIVATED
                                               MACHINE
                                              ACTIVATION
                                                STATUS


PRESS HERE TO TURN THE
   MODEM ON OR OFF
       MANUALLY                                                                         PRESS HERE FOR
                                                                                        CONTACTS



                                                                                   ENTER THE 4 MANUAL CODES
 11 MACHINE CODES FOR                                                                “CODES GIVEN BY RYO”
 MANUAL REACTIVATION.
“CODES TO GIVE TO RYO”                                                            PRESS HERE TO VALIDATE THE
                                                                                 CODES, CHECK AND CONFIRM THE
                                                                                 CODES AGAIN BEFORE PRESSING
  PRESS HERE TO TO
                                                                                    KEEPS TRACK OF THE FAILED
RETURN TO MAIN SCREEN
                                                                                      RELOADING ATTEMPTS
                                                                                   KEEPS TRACK OF THE GOOD
                                                                                     RELOADING ATTEMPTS




           POWER LED, WILL              CURRENT        CURRENT TUBES
            ALWAYS BE ON                 BATCH      CREDITED, “AMOUNT OF
              WHEN THE                  CREDITED    GOOD CIGARETTES THAT
             MACHINE IS                              CAN BE ROLLED (BAD
              RECEIVING                                TUBES ARE NOT
               POWER                                     COUNTED)


                                                                                                     PG. 54
                          Extra Screen

PRESS HERE TO RESET THE
        ALARMS
                                                     DIFFERENT SYSTEM
                                                        INFORMATION
                                            PLC STATUS (DEBUG)
 EXIT RUNTIME, NEEDS A
                                            F0 NORMAL IS 2041
 PASSWORD (CALL RYO)
                                            F1 NORMAL IS 5000
PRESS HERE TO ENABLE OR
  DISABLE THE BUZZER                        F2 NORMAL IS 0

   RETURN TO SETUP                                 HMI & PLC SOFTWARE
       SCREEN                                            VERSION




                            PRESS HERE TO
                                VIEW
                           INPUTS/OUTPUTS




                                                                        PG. 55
                             I / O Screen
                              REFER TO THE ELECTRICAL
                               DRAWINGS FOR ADDRESS
                                   INFORMATION

                                                         RETURN TO SETUP
                                                             SCREEN


PRESS HERE TO RESET THE
        ALARMS


                                                                           DISPLAY THE STATUS OF
                                                                                THE OUTPUTS
  DISPLAY THE STATUS OF
        THE INPUTS

 FORCES THE CASSETTE TO
  GO UP OR DOWN (NOTE 1)

  PRESS HERE TO GO TO THE
     I/O TEST SCREEN, A                                                    5 COUNTERS TO DETECT
   PASSWORD IS REQUIRED.                                                    WHICH MOTOR WAS ON
     (CALL RYO, NOTE 1)                                                    WHILE THE 12 VDC POWER
                                                                            SUPPLY WAS SHORTED


                                                        PRESS HERE
                                                        TO CHANGE
                                                         LANGUAGE
           POWER LED, WILL
            ALWAYS BE ON
              WHEN THE
             MACHINE IS
                                NOTE 1: MACHINE MUST
              RECEIVING
                               NOT BE IN THE RUN MODE
               POWER
                              (PRODUCTION) FOR THESE
                              BUTTONS TO WORK, STOP
                                (PAUSE) THE MACHINE
                                                                                            PG. 56
                            I / O Test Screen
                                REFER TO THE ELECTRICAL
                                 DRAWINGS FOR ADDRESS
                                     INFORMATION

                                                          RETURN TO SETUP
                                                              SCREEN

 PRESS HERE TO RESET
       ALARMS


                                                                        PRESS HERE TO CLEAR ALL
                                                                           MANUAL OVERRIDES
 DISPLAYS THE STATUS OF
       THE INPUTS
                                                                             DISPLAY THE STATUS OF THE
                                                                              OUTPUTS. PRESS ONCE TO
FORCES THE FORMER TO
                                                                            FORCE ON, PRESS ONCE MORE
 DIFFERENT POSITIONS
                                                                               TO FORCE OFF. (NOTE 1)


                                                                        5 COUNTERS TO DETECT
                                                                         WHICH MOTOR WAS ON
                                                                        WHILE THE 12 VDC POWER
                                                                         SUPPLY WAS SHORTED




                                         PRESS HERE                       NOTE 1: THE INTERFERENCE
          POWER LED, WILL
                                         TO CHANGE                      INTERLOCKS ARE STILL ACTIVE
           ALWAYS BE ON
                                          LANGUAGE
             WHEN THE
            MACHINE IS                                                 ONCE YOU LEAVE THIS PAGE, ALL
             RECEIVING                                                 THE MANUAL OVERRIDES WILL BE
              POWER                                                               RESET


                                                                                            PG. 57
                                  Morning Screen
                             THIS SCREEN WILL BE DISPLAYED EVERY MORNING AT 6 AM, UNTIL
                                            YOU PRESS THE DONE BUTTON




MAINTENANCE LIST TO DO
    EVERY MORNING




                                                                                           PRESS HERE TO
                                                                                          CHANGE LANGUAGE

                                                      PRESS HERE TO
                                                     RELOAD MACHINE
                                                     CREDIT (NOTE 1)
                                                                                PRESS HERE TO
           POWER LED, WILL        CURRENT     CURRENT CIGARETTES                CONFIRM THAT
            ALWAYS BE ON           BATCH     CREDITED, “AMOUNT OF             MAINTENANCE WAS
              WHEN THE            CREDITED   GOOD CIGARETTES THAT              DONE, PASSWORD
             MACHINE IS                          CAN BE ROLLED                PROTECTED (CODE =
              RECEIVING                           (PURCHASED)                        123)
               POWER
                                                                NOTE 1: MACHINE MUST NOT BE IN USE,
                                                                  PLEASE FINISH BATCH OR CANCEL.
                                                                                                            PG. 58
                             Power up, Screen
                       THE HMI SCREEN WILL SHOW UP EVERY TIME THAT THE MACHINE
                                              POWERS UP




PRESS HERE FOR
CONTACTS




                                                                                  PRESS HERE TO
   CLOCK OR                                                                      CHANGE LANGUAGE
    ALARM
   MESSAGES




                                           PRESS HERE TO START
           POWER LED, WILL
                                           THE BARREL CLEANING
            ALWAYS BE ON
                                                SEQUENCE
              WHEN THE
             MACHINE IS
              RECEIVING
               POWER


                                                                                          PG. 59
                       Indexer Alarm Screen
                       THIS SCREEN WILL BE DISPLAY AUTOMATICALLY ON INDEXER ALARMS

                         HIDDEN BUTTON TO ACCES SETUP SCREEN, PRESS 3 TIME WITH IN
                          2 SECONDS. THIS WILL BRING YOU TO THE PASSWORD SCREEN




PRESS HERE TO RESET
 ALARMS, PASSWORD
PROTECTED (CODE 852,
      NOTE 1)



                                                                                      CURRENT ALARM LIST




    POWER LED, WILL
     ALWAYS BE ON
       WHEN THE                                          PRESS HERE TO CHANGE
      MACHINE IS                                         PAGE IF MORE THAN ONE
       RECEIVING                                             PAGE PRESENT
        POWER
                  NOTE 1: THIS SCREEN WILL CLOSE AUTOMATICALLY WHEN YOU PRESS THE RESET
                   BUTTON, IF AN INDEXER ALARM IS STILL PRESENT, THIS SCREEN WILL REAPPEAR
                    AUTOMATICALLY, IF NO INDEXER ALARM IS PRESENT BUT OTHER ALARMS ARE
                               PRESENT, THE GENERAL ALARM SCREEN WILL APPEAR                         PG. 60
                  General Alarm Screen
                THIS SCREEN WILL BE DISPLAY AUTOMATICALLY ON ALL ALARMS EXCEPT FOR
                                          INDEXER ALARMS
                      HIDDEN BUTTON TO ACCES SETUP SCREEN, PRESS 3 TIME WITH IN
                       2 SECONDS. THIS WILL BRING YOU TO THE PASSWORD SCREEN




PRESS HERE TO RESET
   ALARMS, NOTE 1




                                                                                  CURRENT ALARM LIST




                                                       PRESS HERE TO CHANGE
        POWER LED, WILL                                PAGE IF MORE THAN ONE
      ALWAYS BE ON WHEN                                    PAGE PRESENT
         THE MACHINE IS
       RECEIVING POWER

                NOTE 1: THIS SCREEN WILL CLOSE AUTOMATICALLY WHEN YOU PRESS THE RESET
                   BUTTON, IF NO INDEXER ALARM IS PRESENT, THIS SCREEN WILL REAPPEAR
                 AUTOMATICALLY IF ALARM ARE STILL PRESENTS. IF INDEXER ALARM IS PRESENT
                 AND OTHER ALARMS ARE PRESENT, THE INDEXER ALARM SCREEN WILL APPEAR               PG. 61
                         Cassette Present Screen
                     THIS SCREEN WILL BE DISPLAYED AUTOMATICALLY AFTER A CLEANING CYCLE AND THAT A
                    CASSETTE IS STILL PRESENT. ON THIS SCREEN YOU HAVE THE OPPORTUNITY TO CONTINUE
                                                      OR TO BE DONE




PRESS HERE TO CONTINUE THE
 CYCLE. “MAKE CIGARETTES”
                                                                                                 PRESS HERE CANCEL,
                                                                                               FLUSH THE TOBACCO AND
                                                                                                RELEASE THE CASSETTE




                   POWER LED, WILL
                    ALWAYS BE ON
                      WHEN THE
                                                  STATUS OF CASSETTE.
                     MACHINE IS
                                                     WILL FLASH IF
                      RECEIVING
                                                  CASSETTE IS PRESENT
                       POWER


                                                                                                          PG. 62
                         Remove Cassette Screen
               THIS SCREEN WILL BE DISPLAYED AUTOMATICALLY AFTER A CASSETTE POSITIONING ERROR OCCURS,
                              YOU NEED TO REMOVE THE CASSETTE AND TUBES TO START AGAIN
                               HIDDEN BUTTON TO ACCES SETUP SCREEN, PRESS 3 TIME WITHIN
                                2 SECONDS. THIS WILL BRING YOU TO THE PASSWORD SCREEN




PRESS HERE TO CONFIRM THAT
  YOU HAVE REMOVED THE
        CASSETTE




                                                                                             CURRENT ALARM LIST




                   POWER LED, WILL
                    ALWAYS BE ON                                PRESS HERE TO CHANGE
                      WHEN THE                                  PAGE IF MORE THAN ONE
                     MACHINE IS                                     PAGE PRESENT
                      RECEIVING
                       POWER


                                                                                                          PG. 63
                        PLC ERROR Screen
                      THIS SCREEN WILL BE DISPLAYED AUTOMATICALLY IF A PLC ERROR
                       OCCURS, IF THE PLC IS NOT IN RUN MODE THE NORMAL SCREEN
                                 CHANGE WILL NOT WORK. CONTACT RYO




                                                                                   GENERAL SYSTEM
                                                                                    INFORMATION
 PLC STATUS (DEBUG)
  F0 NORMAL IS 2041
  F1 NORMAL IS 5000
    F2 NORMAL IS 0

EXIT RUNTIME, NEEDS A                                                              PRESS HERE TO CLOSE
PASSWORD (CALL RYO)                                                                      SCREEN
  DISREGARD ANY
ALARMS SHOWN HERE




                                                                                                    PG. 64
       Screen Saver
THIS SCREEN WILL BE DISPLAYED AUTOMATICALLY AFTER 10
 MINUTES THAT THE MAIN SCREEN IS DISPLAYED. THE TWO
        IMAGES WILL TOGGLES EVERY 4 SECONDS




 PRESS ANYWHERE ON THE SCREEN TO START A CYCLE




                                                       PG. 65

								
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