---
title: Machine Manual - Boxmat PROi
description: Boxmat PROi Manual and Training Videos to better serve our customers. If you need extra training or support please contact service@weldmaster.com
---

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# Boxmat PROi Manual

[Pre-Install Machine ](https://www.weldmaster.com/pre-install/boxmatpro)

## Boxmat PROi Operation Manual

[![Boxmat PROi-Main Image](https://www.weldmaster.com/hs-fs/hubfs/Boxmat%20PROi-Main%20Image.png?width=600&height=451&name=Boxmat%20PROi-Main%20Image.png)](https://cta-redirect.hubspot.com/cta/redirect/5530045/7c32cfb1-414a-41a3-98c8-1339fb7243ef)

This instruction manual is intended to be a guide when operating the Boxmat PRO INTELIGO. To ensure optimal performance from your welder, please follow the recommendations and specifications precisely.

## Table of Contents

- **[Chapter 1: Introduction](https://www.weldmaster.com/manuals/boxmatproi#T3-Manual-1)**
- **[Chapter 2: Health and Safety Regulations](https://www.weldmaster.com/manuals/boxmatproi#T3-Manual-2)**
- [**Chapter 3: Technical Data**](https://www.weldmaster.com/manuals/boxmatproi#T3-Manual-3)
- **[Chapter 4: Technical Specifications](https://www.weldmaster.com/manuals/boxmatproi#T3-Manual-4)**
- **[Chapter 5: Installation](https://www.weldmaster.com/manuals/boxmatproi#T3-Manual-5)**
- [**Chapter 6: Machine Operation**](https://www.weldmaster.com/manuals/boxmatproi#T3-Manual-7)
- **[Chapter 7: Description of HMI Panel Screen](https://www.weldmaster.com/manuals/boxmatproi#T3-Manual-8)**
- [**Chapter 8: Maintenance**](https://www.weldmaster.com/manuals/boxmatproi#boxmat-maintenance)
- [**Chapter 9: Occupational and Safety Rules**](https://www.weldmaster.com/manuals/boxmatproi#boxmat-occupational-safety)
- [**Chapter 10: Electrical Documentation**](https://www.weldmaster.com/manuals/boxmatproi#boxmat-electrical-documentation)
- [**Chapter 11: Pneumatic Documentation**](https://www.weldmaster.com/manuals/boxmatproi#boxmat-pneumatic-documentation)
- [**Chapter 12: Utilization and Machine**](https://www.weldmaster.com/manuals/boxmatproi#boxmat-utilization)[** Breaking**](https://www.weldmaster.com/manuals/boxmatproi#boxmat-utilization)
- [**Chapter 13: Enclosures**](https://www.weldmaster.com/manuals/boxmatproi#boxmat-enclosures)
- **[Chapter 14: ](https://www.weldmaster.com/manuals/boxmatproi#T3-Manual-11)[Additional Machine Documents](https://www.weldmaster.com/manuals/boxmatproi#Manual)**

For more technical information regarding this machine call our Resolution Center at 1-855-888-WELD or email service@weldmaster.com.

**1.0 Introduction**

Boxmat PRO is the most modern and most versatile machine on the market and revolutionizes the production of corrugated packaging. Thanks to the automatic and tool-free change of settings on the HMI touch panel which can be changed within a few seconds, any product size may be programmed in standard, FEFCO types. PRO is ideal for the production of short series as well as for large, mass production. Slot-cutting, the removal of excess material, scoring, the removal of tongues of adhesive, as well as cutting the format to size, is carried out in one cycle without the need for additional attachment.

In ‘one go’, boxes of 3/5 layers of corrugated cardboard can be made. More than one box can be made from a suitably large format in just a single cycle.

The positions of the longitudinal tools are set using servo drives depending on the required size and thickness of the cardboard. Formats are centrally positioned for automatically positioned bumpers. A set of non-slip rollers and input-output shafts ensures precise and stable carton guidance throughout the entire cycle.

The innovative system applied, using circular knives, allows excess, or waste cardboard to be cut off from the remainder of the sheet. This solution facilitates the bi-directional correction of the size of the sheets and enables the sheets currently in production, to be cut to different sizes simultaneously, without having to be cut on a separate, peripheral device.

**FEATURES:**

- Notching, bi-directional scoring and cutting off waste in one cycle
- One integrated module for cutting, scoring and cutting off, eliminates production errors in multi-module machines
- Quick change of machine settings, on the touch panel, thanks to servo drives
- Possibility of longitudinal scoring which is a scoring function, transverse scoring and cutting sheets into smaller pieces - a crevice tool
- 4 knives + 4 longitudinal scoring wheels adjustable on the panel - a standard option
- An integrated punching system for cutting holes
- Ecological power and drive system as well as low power consumption
- Selection of styles, sizes, functions and the depths of the scores, using the touch screen
- Cardboard feeder with a reliable pick-up system
- Vibro-insulating legs preventing transmission of vibrations
- Secure and fast remote machine calibration and updating, thanks to remote internet connection
- Easy exchange of scoring wheels and cutting blades

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-06-52-11-84-PM.png?width=30&name=image-png-Jan-31-2022-06-52-11-84-PM.png) ATTENTION:** **Any** **intention** **of** **using** **this** **machine** **for** **any** **purpose other** **than** **as** **described** **in** **this** **manual** **must** ***always**** ***be** **discussed with the manufacturer.**

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-06-52-11-84-PM.png?width=30&name=image-png-Jan-31-2022-06-52-11-84-PM.png) ATTENTION:** **For** **the** **safety** **of** **all** **operators** **and** **other** **personnel,** **it is** **important** **that** **this** **manual** **is** **read** **and** **understood** **by** **all personnel;** **all** **instructions** **should** **be** **followed.**

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-06-52-11-84-PM.png?width=30&name=image-png-Jan-31-2022-06-52-11-84-PM.png) ATTENTION:** **It** **is** **highly** **recommended** **that** **each** **operator,** **once trained** **to** **use** **this** **machine,** **should** **append** **their** **name** **and signature to the** **form** **in** **this manual.**

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-06-52-11-84-PM.png?width=30&name=image-png-Jan-31-2022-06-52-11-84-PM.png) ATTENTION:** **This** **machine** **was** **designed** **for** **use** **by** **able-bodied** **operators.** **Please** **contact** **the** **manufacturer** **for** **help** **and** **advice** **if it needs** **to be** **adjusted or modified for others.**

**2.0 Health and Safety Regulations, Signs and Labels**

**The health and safety of operators and of other personnel within the vicinity of this machine, is of paramount importance.**

**In order to use this machine safely, it is very important that this manual is read thoroughly by all personnel who intent to work with, or near the machine. All safety instructions should be adhered to, including the warning labels in the manual, as well as those displayed on the machine.**

**It is imperative that the purchaser be obliged to work out their own WORKSTATION INSTRUCTIONS for their machine operators, using the instructions in this service manual and the knowledge derived from the manufacturer's own experience of the technology of the product.**

**The ultimate, legal and financial responsibilities for all the potential events that may occur, due either to ignorance of this service manual or ignorance of Occupational Health and Safety regulations, lies with the purchaser. It is, therefore, ESSENTIAL to read and follow the safety instructions.**

**Warning Signs**

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-06-52-11-84-PM.png?width=30&name=image-png-Jan-31-2022-06-52-11-84-PM.png) ATTENTION:** **Each** **operator** **MUST** **read** **the** **text** **of** **this** **service** **manual** **before** **undertaking** **any** **work** **with** **the** **machine.**

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-06-52-11-84-PM.png?width=30&name=image-png-Jan-31-2022-06-52-11-84-PM.png) ATTENTION:** **The** **purchaser** **is** **strongly** **advised** **to** **draw** **up their** **own ****WORKSTATION** **INSTRUCTIONS** **for the machine operators,** **on** **the** **basis** **of** **the** **text** **included** **in** **this** **service manual** **and** **the** **knowledge** **derived** **from** **their** **own production technology.**

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-06-57-55-33-PM.png?width=70&name=image-png-Jan-31-2022-06-57-55-33-PM.png) ATTENTION:** **UNDER** **NO** **CIRCUMSTANCES** **should** **the ****machine** **be** **operated** **by** **unqualified** **personnel.** **Machine operators** **must** **be** **familiar** **with** **Occupational** **Health** **and** **Safety** **regulations** **with** **special** **focus** **on** **the** **risks** **inherent in** **this** **machine*.**** ***As** **a** **consequence** **of** **the** **aforesaid, documentation,** ***approving**** ****completion**** ****of**** ****training**** ****and**** ****signed by**** ****the**** ****trained**** ****operator, *should** **be** **issued.**

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-06-52-11-84-PM.png?width=30&name=image-png-Jan-31-2022-06-52-11-84-PM.png) ATTENTION:** **The** **machine** **was** **not** **designed** **to** **be** **operated** **by disabled** **operators.** **If** **the** **need** ***arises**** ****-**** ****and**** ****after**** ****prior consultation**** ****with**** ****the**** ****Manufacturer-**** ***the** **machine** **can** **be appropriately adjusted for disabled** **operators.**

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-06-52-11-84-PM.png?width=30&name=image-png-Jan-31-2022-06-52-11-84-PM.png) ATTENTION:** **According** **to** **the** **manufacturer's** **recommendations****, the** **machine** **should** **be** **installed** **in** **an** **industrial** **environment *****only*****.**

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-06-52-11-84-PM.png?width=30&name=image-png-Jan-31-2022-06-52-11-84-PM.png) ATTENTION:** **Careless** **handling** **of** **the** **machine,** **during** **transport** **and/or** **relocation, may** **lead to severe** **injury** **or accidents.**

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-06-58-42-65-PM.png?width=40&name=image-png-Jan-31-2022-06-58-42-65-PM.png) ATTENTION:** **Periodical,** **adequate** **preventive** **inspection** **of** **the fire** **protection** **system** **should** **be** **carried** **out,** **in** **and** **around** **the machine.** **The** **purchaser** **is** **fully** **responsible** **for** **arranging** **to conduct** **such inspections.**

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-06-58-42-65-PM.png?width=40&name=image-png-Jan-31-2022-06-58-42-65-PM.png) ATTENTION:** **A** **life** **threatening,** **high-power** **network** **voltage** **of** **3** **x** **480V;** **50...60** **Hz** **is** **supplied** **to** **the** **machine.** **As** **a** **result,** **all** **servicing** **should** **be** **undertaken** **by** **appropriately** **qualified** **personnel *only*,** **as** **required by** **law.**

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-07-01-33-50-PM.png?width=100&name=image-png-Jan-31-2022-07-01-33-50-PM.png)ATTENTION:** **Work** **carried** **out** **in** **the** **feeding,** **cutting** **or** **bending** **zones** **within** **the** **systems,** **should** **be conducted** **by** **qualified** **personnel** ***only,**** ***after** **taking** **all ****precautionary** **measures****.** **In** **the** **above-mentioned zones,** **higher** **instances** **of** **potential** **body** **injury** **are possible.**

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-07-02-42-66-PM.png?width=60&name=image-png-Jan-31-2022-07-02-42-66-PM.png) ATTENTION:** **The** **EMERGENCY** **STOP** **button** **is** **designed** **to be** **pressed** **at** **any** **time** **but** **especially** **when** **an** **emergency** **shutdown** **is** **urgently** **needed.**

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-07-03-13-64-PM.png?width=40&name=image-png-Jan-31-2022-07-03-13-64-PM.png)ATTENTION:** **The** **area** **surrounding** **the** **machine** ***should**** ****not**** ***be blocked** **by** **any** **objects,** **as** **this** **may** **result** **in** **personnel** **stumbling,** **sliding and falling which may** **lead to severe** **injury.**

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-06-52-11-84-PM.png?width=30&name=image-png-Jan-31-2022-06-52-11-84-PM.png) ATTENTION:** **The** **operator should** **always** **ensure** **that all doors, lids,** **shields** **and other** **protective devices** **are** **securely** **in place** **before** **the machine** **is** **started.**

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-06-52-11-84-PM.png?width=30&name=image-png-Jan-31-2022-06-52-11-84-PM.png) ATTENTION: An** **operator** **must** ***never****** *climb** **onto the** **machine** **when it is in operation.**

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-06-52-11-84-PM.png?width=30&name=image-png-Jan-31-2022-06-52-11-84-PM.png) ATTENTION: The through-route** **of the** **corrugated** **board must NEVER** **be** **blocked** **by** **personnel or** **by** **any** **obstacle.**

**Prohibitory and Mandatory Signs**

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-07-07-35-86-PM.png?width=60&name=image-png-Jan-31-2022-07-07-35-86-PM.png) UNDER** **NO** **CIRCUMSTANCES** **should** **the** **machine** **be** **operated by** **untrained** **personnel.** **The** **machine’s** **operators** **must** **be familiar** **with** **Occupational** **Health** **and** **Safety** **regulations** **with special** **focus on the** **risks** **inherent in this** **machine*****.*****

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-07-08-07-04-PM.png?width=60&name=image-png-Jan-31-2022-07-08-07-04-PM.png) ATTENTION:** **UNDER** **NO** **CIRCUMSTANCES** **should** **the ****machine** **be** **operated** **by** **unqualified** **personnel.** **Machine operators** **must** **be** **familiar** **with** **Occupational** **Health** **and** **Safety regulations.**

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-07-08-18-99-PM.png?width=100&name=image-png-Jan-31-2022-07-08-18-99-PM.png) UNDER** **NO** **CIRCUMSTANCES** **should** **the** **machine** **be assembled,** **dismantled** **or** **transported** **by** **untrained** **personnel,** **nor** **by** **those** **unfamiliar** **with** **the** **safety regulations** **included** **in** **this** **service** **manual,** **since** **such** **activities** **may** **lead** **to** **an** **accident** **or** **to** **financial loss.**

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-07-08-50-27-PM.png?width=60&name=image-png-Jan-31-2022-07-08-50-27-PM.png) UNDER** **NO** **CIRCUMSTANCES** **should** **servicing** **or** **maintenance** **be** **conducted,** **or** **preventive** **measures** **be** **taken,** **without fully** **disconnecting from the electrical** **supply.**

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-07-09-20-80-PM.png?width=60&name=image-png-Jan-31-2022-07-09-20-80-PM.png) UNDER** **NO** **CIRCUMSTANCES** **should** **any** **of** **the** **sub-** **assemblies,** **such** **as** **the** **guide** **rollers,** **the** **cutting** **or** **scoring** **tools,** **be** **touched.**

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-07-07-35-86-PM.png?width=60&name=image-png-Jan-31-2022-07-07-35-86-PM.png) UNDER** **NO** **CIRCUMSTANCES** **should** **any** **measures** **be** **undertaken** **which** **could** **lead** **to** **a** **reduction** **in** **the** **machine’s** **safety** **status;** **this** **includes such** **measures** **as blocking** **master** **switches, removing guards** **or disconnecting sensors,** ***etc.***

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-07-07-35-86-PM.png?width=60&name=image-png-Jan-31-2022-07-07-35-86-PM.png) UNDER NO** **CIRCUMSTANCES** **should** **an** **operator** **climb** **onto the machine** **during the** **loading procedure** **or during its regular** **work** **cycle.**

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-07-11-11-91-PM.png?width=60&name=image-png-Jan-31-2022-07-11-11-91-PM.png) UNDER** **NO** **CIRCUMSTANCES** **should** **any** **potential** **fire,** **near** **the** **machine,** **be** **extinguished** **with** **water.** **Use** **only** **licensed,** **sophisticated,** **firefighting** **agents** **and** **fire-hazard** **protection** **products.**

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-07-11-30-54-PM.png?width=60&name=image-png-Jan-31-2022-07-11-30-54-PM.png)UNDER ****NO CIRCUMSTANCES should the guards be removed during the machine’s work cycle.**

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-07-12-38-02-PM.png?width=60&name=image-png-Jan-31-2022-07-12-38-02-PM.png) UNDER** **NO** **CIRCUMSTANCES** **should** **the** **machine** **be** **sprayed** **with water during** **its regular** **work** **cycle** **or** **when it is** **idle.**

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-07-12-54-14-PM.png?width=60&name=image-png-Jan-31-2022-07-12-54-14-PM.png)****UNDER ****NO ****CIRCUMSTANCES ****should ****any ****maintenance ****tasks ****be ****conducted while ****the ****machine ****is ****in operation.**

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-07-15-43-31-PM.png?width=60&name=image-png-Jan-31-2022-07-15-43-31-PM.png) UNDER** **NO** **CIRCUMSTANCES** **should** **any** **oil,** **solvent** **or** **any other** **caustic** **or** **toxic** **substances** **be** **poured** **out,** **either** **in** **or near** **the** **machine.**

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-07-16-02-48-PM.png?width=60&name=image-png-Jan-31-2022-07-16-02-48-PM.png) UNDER** **NO** **CIRCUMSTANCES** **should** **mobile** **phones** **be** **used in the** **immediate** **vicinity of the machine.**

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-07-16-17-97-PM.png?width=60&name=image-png-Jan-31-2022-07-16-17-97-PM.png) UNDER** **NO** **CIRCUMSTANCES** **should** **any** **naked** **flame** **be** **used in the** **immediate** **vicinity of the machine.**

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-07-16-39-47-PM.png?width=60&name=image-png-Jan-31-2022-07-16-39-47-PM.png) UNDER ****NO ****CIRCUMSTANCES** **should** **cigarettes** **be** **smoked** **in the immediate** **vicinity** **of the** **machine.**

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-07-18-15-54-PM.png?width=60&name=image-png-Jan-31-2022-07-18-15-54-PM.png) UNDER** **NO** **CIRCUMSTANCES** **should** **alcohol** **be** **drunk** **in** **the** **immediate** **vicinity** **of** **the** **machine,** **nor** **should** **personnel,** **under the** **influence of alcohol,** **operate the** **machine.**

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-07-18-42-51-PM.png?width=60&name=image-png-Jan-31-2022-07-18-42-51-PM.png) UNDER** **NO** **CIRCUMSTANCES** **should** **personnel** **eat** **in** **the immediate** **vicinity of** **the machine.**

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-07-19-07-12-PM.png?width=60&name=image-png-Jan-31-2022-07-19-07-12-PM.png) IT** **IS** **STRONGLY** **ADVISED** **that** **each** **person,** **assigned** **to** **operate** **the** **machine,** **be** **fully** **trained.** **The** **scope** **of** **training** **should** **cover** **operation** **of** **the** **machine,** **as** **well** **as** **Occupational** **Health** **and** **Safety** **regulations,** **with** **special** **focus** **on** **the** **risks** **inherent** **in** **the machine.**

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-07-19-29-78-PM.png?width=60&name=image-png-Jan-31-2022-07-19-29-78-PM.png) IT** **IS** **HIGHLY** **RECOMMENDED** **that** **ALL** **covers** **and** **guards,** **designed** **for the machine,** **be** **used.**

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-07-20-01-73-PM.png?width=60&name=image-png-Jan-31-2022-07-20-01-73-PM.png) IT** **IS** **ESSENTIAL** **that** **in** **the** **event** **of** **any** **accident** **involving** **the operator,** **or** **any** **machine** **failure,** ***both**** ***should** **be** **reported** **to the management** **promptly.**

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-07-20-21-65-PM.png?width=60&name=image-png-Jan-31-2022-07-20-21-65-PM.png) IT** **IS** **ESSENTIAL** **to** **wear** **safe,** **close-fitting,** **workwear** **to reduce** **the** **possibility** **of** **being** **snagged** **or** **pulled** **into** **the machine.**

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-07-20-41-31-PM.png?width=60&name=image-png-Jan-31-2022-07-20-41-31-PM.png) IT** **IS** **ESSENTIAL** **to** **wear** **protective** **gloves** **while** **operating** **the machine.**

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-07-22-09-20-PM.png?width=60&name=image-png-Jan-31-2022-07-22-09-20-PM.png) IT IS** **ESSENTIAL to** **wear** **anti-slip working footwear.**

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-07-22-25-89-PM.png?width=60&name=image-png-Jan-31-2022-07-22-25-89-PM.png) Hearing** **protection must be** **worn** **in this** **area.**

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-07-22-43-91-PM.png?width=60&name=image-png-Jan-31-2022-07-22-43-91-PM.png) IT** **IS** **ESSENTIAL** **that** **long** **hair** **be** **tied** **back** **in** **such** **a** **way** **as** **to** **reduce** **the** **risk** **of** **being** **snagged** **or** **pulled** **into** **the** **machine; operators** **must** **wear** **either** **appropriate** **hair** **covering** **or** **wear their** **hair** **tied** **up.**

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-07-22-57-10-PM.png?width=60&name=image-png-Jan-31-2022-07-22-57-10-PM.png) IT** **IS** **ESSENTIAL** **to** **keep** **the** **floor** **around** **the** **machine** **clean** **and** **clear of any** **paper,** **board or** **other** **waste.**

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-07-23-13-61-PM.png?width=60&name=image-png-Jan-31-2022-07-23-13-61-PM.png) IT** **IS** **REQUIRED** **that** **all** **machine** **operators** **are** **well-trained** **personnel,** **acquainted** **with** **Occupational** **Health** **and** **Safety** **regulations;** **they** **should** **also** **be** **familiar** **with** **all** **hazardous** **situations** **likely** **to** **occur** **in** **the** **operation** **of** **sophisticated** **machines** **of this** **complexity.**

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-07-23-13-61-PM.png?width=60&name=image-png-Jan-31-2022-07-23-13-61-PM.png) IT** **IS** **ESSENTIAL** **to** **use** **the** **emergency** **stop** **switch** **button whenever the** **operator's** **life** **or health** **is at risk.**

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-07-23-13-61-PM.png?width=60&name=image-png-Jan-31-2022-07-23-13-61-PM.png) IT** **IS** **ESSENTIAL** **to** **disconnect** **the** **machine** **from** **the** **power** **supply** **whenever** **servicing,** **maintenance** **or** **preventive** **activities are** **underway.**

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-07-23-36-52-PM.png?width=60&name=image-png-Jan-31-2022-07-23-36-52-PM.png) During** **packing,** **unpacking** **and** **transportation,** **special** **measures** **should** **be** **taken,** **in** **order** **to** **prevent** **the** **machine** **from tipping over.**

**3.0 ****Technical Data**

| **Type** | ***Boxmat**** ****PRO**** ****INTELIGO*** |
| --- | --- |
| Material | single, double up to 1/4”, up to 1050 g/m2 |
| Power supply | 3 x 230 VAC; 50/60 Hz |
| Control voltage | 24 VDC |
| Installed power | 5.5 kW |
| Working pressure in pneumatic system | 0.6 – 0.8 MPa |
| Filtration accuracy [(FR [filter reducer] system) | 20 μм |
| Demanded class of working medium activity in pneumatic system | 4-4-4 according to ISO8573-1 standards |
| Efficiency | up to 600 sheets per hour |
| Carton’s styles | 40 pre-set FEFCO styles + free style |
| Recipe memory | 1000 items for FEFCO + 1000 items for freestyle |
| Maximum board size | 94” width x 300” length (single sheet) |
| Minimum board size | 10” width x 25 ½“ length |
| Distance between slotting knives | 2 ¾“ – 78 ¾“ (with 8” knives) |
| Width of slot | 5/16“ |
| Minimum panel size | ¾” |
| Glue flap | option to choose the length of the flap |
| Machine dimensions | 134” x 63” x 63” (L x W x H) |
| Weight | 2800 kg (6200 lbs) |

**4.0 Technical Specifications**

- The Boxmat Pro machine consists of the main body, containing all the electrical and mechanical components, and movable work table. The main body is based on a metal frame ensuring the adequate level of stability. The work table is designed to assist the operators feeding the corrugated material through the machine.
- The corrugated blanks are carried through the machine by a series of rollers and wheels driven by servo-drives. In a similar way the slotting beam is propelled by a servo drives.
- Behind the slotting/scoring beam is the innovative system of rotary tools that enable the operator to cut off excess board and eject them without any cuts or scores enabling them to be re-used for smaller boxes. This also allows oversized blanks to be trimmed to size as they pass through the machine instead of having to trim on another, separate machine.
- It also allows the production of two boxes at one time (with Multi-production option), if box size and sheet size are suitable by attaching a central knife.
- The slots are punched out by a system of blades attached to the scoring beam.
- The slotting blades are automatically moved to the correct positions by asynchronous motors driven by the inverter and encoder, once the dimensions is entered into the touch screen.
- The left hand guide is positioned automatically and, once a board blank is positioned against it, the right hand guide can be slid up to it to allow the blank to pass through the machine without any twisting.
- The machine is equipped with a full set of covers and guards to protect operators from the moving blades and knives. To comply with all European safety regulations, the machine will not operate if these are not all in place and an appropriate error message will be displayed on the screen.

**5.0 Installation**

The manufacturer will ensure that the machine is appropriately packaged for transport. The type and strength of packaging are adapted to the distance and means of transport used, as well with regard to the potential risks associated with the means of transport used. The Manufacturer suggests that Recipients use the Manufacturer's means of transport and service personnel.

Storage of an unused machine does not imply any requirements other than a suitable storage environment. Warehousing must provide sufficient protection against atmospheric agents and be dry, with an acceptable humidity level below 70%. The storage temperature should be between 5 ºC and 40 ºC.

Adequate anti-corrosion protection should be ensured, especially for metal parts which, for technical reasons, have not been painted or protected against corrosion.

If the machine is delivered in a crate and/or covered with film-wrap that creates an anti-corrosive atmosphere, the machine should remain in the same, throughout the entire storage period.

To protect against moisture, it is recommended that the machine is not stored on the floor of the warehouse but on pallets, in order to keep it lifted off the floor.

*![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-07-29-30-89-PM.png?width=80&name=image-png-Jan-31-2022-07-29-30-89-PM.png)*

 

*This** **box maker** **should** **be** **stored** **vertically** **in** **a** **dry** **and** **well** **ventilated** **room.** **The** **machine** **is** **sensitive** **to** **vibration,** **shock,** **violent** **jolts** **and** **long-lasting** **tilts.** **Even** **if** **it** **is** **dropped** **from** **a relatively** **insignificant** **height** **this** **may** **lead** **to** **its** **permanent** **and** **irreversible damage.***

The above provisions are intended to make all persons and services, who have contact with this device, aware of its high sensitivity to any impactful stimuli and, at the same time, aware also, that **no** **claims,** **arising** **from** **such** **permanent** **damage,** **as** **described above**, **will** **be** **considered as** **a** **valid** **complaint.**

For further advice or information, please contact the manufacturer’s service technicians.

**Transport**

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-07-32-36-89-PM.png?width=140&name=image-png-Jan-31-2022-07-32-36-89-PM.png) UNDER** **NO** **CIRCUMSTANCES** **should** **the** **machine** **be assembled,** **dismantled** **or** **transported** **in** **any** **way** **by unqualified** **personnel** **or** **those** **unfamiliar** **with** **the safety** **and** **care** **information** **included** **in** **this** **manual. Failure** **to** **comply** **with** **this** **basic** **rule** **may** **lead** **to accidental** **damage** **or** **injury** **not** **covered** **by** **the manufacturer’s warranty or liability.**

- The entity responsible for transporting and installing the machine at the Ordering Party's plant should be determined at the contract signing stage, however at the latest, after the technical acceptance of the machine at the Manufacturer's plant and before being issued to the Ordering Party.
- Due to the nature of the device, the Manufacturer suggests that the Recipients use the Manufacturer's means of transport and service personnel.
- The machine should be moved using lifting devices such as cranes, forklift trucks or pallet trucks, all of which should have sufficient lifting capacity for the purpose of safe transportation. The persons operating them should have the required permits and the training, as required by law.
- The correct mode of transportation for **BOXMAT** **PRO** machines is presented below.

![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-08-10-35-87-PM.png?width=600&name=image-png-Jan-31-2022-08-10-35-87-PM.png)

Fig. 2. The location for lifting the machine is indicated by the pictogram (Fig. 2 -1)

![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-08-12-13-30-PM.png?width=600&name=image-png-Jan-31-2022-08-12-13-30-PM.png)

Fig. 3. The correct transportation of the machine using a forklift truck

**It is forbidden to lift the BOXMAT PRO machine where so indicated by pictograms; the drawing below refers.**

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-08-14-20-24-PM.png?width=600&name=image-png-Jan-31-2022-08-14-20-24-PM.png)**

Fig. 4. It is forbidden to lift the BOXMAT PRO machine by its side walls, using a forklift truck.

***![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-06-52-11-84-PM.png?width=30&name=image-png-Jan-31-2022-06-52-11-84-PM.png) ATTENTION:** **Failure** **to** **comply** **with** **the** **above** **pictograms** **and methods** **of** **assembly,** **may** **result** **in** **damage** **to** **the** **machine's structure** **and** **components.*****

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-06-52-11-84-PM.png?width=30&name=image-png-Jan-31-2022-06-52-11-84-PM.png) ATTENTION: Machine** **must** **be** **transported vertically.**

It is essential that the machine, and all parts and accessories, must be packaged safely and securely. Suitable protective wrapping, pallets and/or crates should be supplied to ensure that the machine and all peripheral parts and accessories arrive for installation safely and undamaged. It is strongly advised to allow the manufacturer to undertake all these tasks to ensure a safe and efficient delivery and installation.

As far as transport procedure is concerned the machine's weight (c. 2800 kg - 6200 lb.) must be taken into account.

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-06-52-11-84-PM.png?width=30&name=image-png-Jan-31-2022-06-52-11-84-PM.png) ATTENTION:** **Careless** **handling** **of** **the** **machine** **during** **transport and/or** **relocation may** **lead to severe** **accidents** **or injuries.**

**Installation**

Installation of the machine at the workplace, is effected by the Ordering Party's personnel, once the contents of these operating instructions and the Manufacturer's services have become familiar to- ***and**** ****have**** ****been**** ****agreed**** ****to****-** *by the Ordering Party’s personnel. The correct setting of the printer is important as a precondition for its optimal functioning and for the comfort and safety of the operators.

Preparation of the location for the machine, the availability and parameters of electrical, pneumatic and ventilation connections, as well as the preparation of the specific design and acceptance requirements, needed to facilitate operation of the machine, is the responsibility of the Ordering Party.

The Manufacturer will provide the necessary guidance and information to assist the Ordering Party in this regard.

After delivering the machine to its designated location, it should be unpacked and leveled. Its technical condition should then be checked and any damage caused in transport, should be rectified.

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-06-52-11-84-PM.png?width=30&name=image-png-Jan-31-2022-06-52-11-84-PM.png) ATTENTION:** **The** **floor** **on** **which** **the** **machine** **is** **to** **be** **placed** **must** **have** **sufficient** **structural** **strength** **to** **support** **the** **weight** **of** **the machine** **and** **any** **vibration** **generated** **by** **the** **normal** **process** **of manufacturing** **boxes.** **It** **should** **also be** **noted** **that** **the** **majority** **of the weight of the** **machine** **is** **concentrated** **at** **the** **feet.**

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-06-52-11-84-PM.png?width=30&name=image-png-Jan-31-2022-06-52-11-84-PM.png) ATTENTION:** **Once** **the** **machine** **is** **leveled** **it** **should** **not** **be** **moved without repeating** **the** **leveling process.**

The most optimal flooring is made of plain concrete of sufficient depth and coated with a thin layer of non-conducting material.

The foundation on which the machine is placed should be architecturally compliant with the building standards and safety rules fulfilling the requirements of depth, strength and level.

**The** **Buyer** **is** **the only person** **responsible** **for preparation of base** **on which the machine** **is supposed to be** **installed.**

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-06-52-11-84-PM.png?width=30&name=image-png-Jan-31-2022-06-52-11-84-PM.png) ATTENTION:** **If** **the** **assembly** **and** **set-up** **procedures** **are** **conducted individually** **by** **the** **purchaser,** **they** **should** **be** **performed** **due** **to** **the instructions** **included** **in** **this** **service** **manual** **and/or** **according** **to the** **instructions** **provided** **by** **the** **manufacturer** **during** **the** **technical** **acceptance** **procedure.**

Use the screws in the machine feet to level the frame. (The sides of the machine's body are the reference plane for level).

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-06-52-11-84-PM.png?width=30&name=image-png-Jan-31-2022-06-52-11-84-PM.png) ATTENTION:** **After** **each** **change** **position** **the** **machine,** **check** **the gap** **between** **the** **upper** **and** **lower** **slotting** **knives.** **On** **the** **entire length** **of** **the** **upper** **slotting** **blades,** **from** **the** **front** **and** **back** **side,** **the gap should not be** **less** **than** **0.004** **inch.**

When the machine is leveled, then the work tables should be assembled and placed at the front and rear of the machine (tables are available on demand). Once both work tables are delivered, they should be leveled to the machine.

**Work Conditions**

**GENERAL INFORMATION**

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-06-52-11-84-PM.png?width=30&name=image-png-Jan-31-2022-06-52-11-84-PM.png) ATTENTION:** **It** **is** **the** **manufacturer’s** **recommendation****,** **that** **the machine should** **be** **installed** **in an industrial** **environment** **only****.**

As written and described within this technical manual, this machine has been designed and manufactured to be used in an industrial environment for the conversion of corrugated fiberboard into a range of cartons and, as such, this machine must be operated within the health and safety regulations associated with the industrial box-making environment.

This machine must not be operated in a potentially explosive atmosphere, in an atmosphere with a high level of pollution, high humidity, high temperatures or in aggressive, or corrosive, fumes.

Due to the electronics and sensors within this machine, it should be used in temperatures from +15°C to +35°C and in a relative humidity ranging from 35% to 85%. Atmospheric humidity condensation, or any potentially aggressive agents, should be avoided.

Temperature changes within the operating environment should not exceed 10°C and the relative humidity should not vary by more than 10%.

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-06-52-11-84-PM.png?width=30&name=image-png-Jan-31-2022-06-52-11-84-PM.png) ATTENTION:** **If** **there** **are** **significant** **temperature** **and** **humidity differences between** **the delivery** **process** **and** **the** **installation** **site,** **the** **machine** **should** **be** **stored** **and** **acclimatized** **in** **the** **site** **where** **it is** **to be** **operated for** **24** **hours** **before** **starting up.**

**LIGHTING**

The criterion for the minimum level of lighting indicates that the acceptable lighting on a horizontal working plane, in rooms where personnel attend for a long time, regardless of what visual tasks are performed, should be 300 lx.

Where, however, there is a degree of visual difficulty greater than average, resulting in difficulties in working, the requirement pertains to ensure higher viewing comfort; this also applies where employees are mostly people over 40 years of age. With this in mind, the level of intensity in the lighting should then be higher than the minimum permissible level of 500 lx.

**5.4.3.** **NOISE**

The device is the source of the noise intensity above 85dB requiring use of plant protection personnel.

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-08-24-42-78-PM.png?width=60&name=image-png-Jan-31-2022-08-24-42-78-PM.png)Hearing protection must be** **worn** **in this** **area!**

We note that all environment have their own noise emissions, which can effectively influence the levels of noise issued by the machine during operation, especially in various technological systems.

**Power Supply Parameters**

**ELECTRIC** **SUPPLY**

The machine must be connected to a power supply of 3 x 480 VAC; 50/60 Hz; (3P+N+PE), equipped with overcurrent protection.

The Buyer's installation must provide shock protection in accordance with PN-EN 60204-1:2018-12.

**COMPRESSED-AIR** **SYSTEM**

The machine uses air pressure ranging from 6-8bar / 85-110 psi.

The filtered impurities are less than 20 µm, to comply with ISO8573-1 4-4-4 standards.

**6.0 Machine Operation**

Assuming that all conditions for the installation and activities described in the previous chapter have been met and successfully carried out, preparations can begin for the first start-up of the machine, in production conditions at the Contracting Party's plant.

Assuming that all conditions for the installation and activities described in the previous chapter have been met and successfully carried out, preparations can begin for the first start-up of the machine, in production conditions at the Contracting Party's plant.

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-06-52-11-84-PM.png?width=40&name=image-png-Jan-31-2022-06-52-11-84-PM.png) ATTENTION:** **Initially,** **the** **machine** **should** **be** **started** **up** **under the supervision of the** **manufacturer’s** **agents*.***

The Service Conditions must be read and understood before starting the machine.

**SERVICE** **CONDITIONS** **–** **GENERAL** **GUIDELINES** **AND** **PROCEDURES**

To ensure correct machine operation, all adjustments and settings must be carried out by the manufacturer's trained technicians, once the machine has been assembled and installed and the initial start-up procedures have been implemented. Corrugated material for testing the machine should be made available by the Buyer.

Before using the machine, that is, prior to its first start-up, the Contracting Party has **the** **absolute** **obligation** **to** train those employees who will be its future operators. Moreover, due to the different work cycles carried out by our machines, in various industrial environments, the Recipient has the **absolute obligation to** create a clear and transparent workplace instruction manual for the device, adapted to its own production cycles.

**UNDER** **NO** **CIRCUMSTANCES** **should** **the** **machine** **be** **operated** **by** **unqualified** **personnel.** **The** **machine** **operators** **must** **be familiar** **with** **the** **occupational** **health** **and** **safety** **rules,** **with** **the focus** **on** **giving** **special** **consideration** **to** **the** **risk** **created** **by using this machine.**

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-08-33-58-52-PM.png?width=80&name=image-png-Jan-31-2022-08-33-58-52-PM.png) ATTENTION:** **The** **Recipient,** **or** **a** **person** **authorized** **by him/her** **on** **the** **basis** **of** **these** **operating** **instructions** **and** **the characteristics** **of** **his/her** **own** **production** **technology,** **has ****the** **absolute** **obligation** **to** **compile** **a** **MACHINE-BASED** **INSTRUCTION MANUAL** **for the employees.**

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-08-35-21-90-PM.png?width=60&name=image-png-Jan-31-2022-08-35-21-90-PM.png)IT** **IS** **STRONGLY** **RECOMMENDED** **to** **instruct** **each** **person** **assigned** **to** **work** **with,** **or** **near,** **this** **machine** **not** **only** **in** **the operating** **of** **the** **machine** **but** **also** **in** **the** **occupational** **health and** **safety** **rules** **associated with operating** **the machine.**

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-08-35-43-76-PM.png?width=60&name=image-png-Jan-31-2022-08-35-43-76-PM.png) The** **setting** **and** **checking** **procedure,** **implemented** **prior** **to using** **this** **machine,** **must** **only** **be** **performed** **by** **trained** **and** **authorized** **personnel.**

**BEFORE** **USING** **THE** **MACHINE** **IT** **IS** **STRONGLY** **RECOMMENDED** **TO** **CHECK** **THE** **FOLLOWING:**

- the effectiveness of protection against electric shock;
- the supply voltage;
- value and phase compliance;
- the emergency buttons (safety switches - **EMERGENCY** **STOP**) if necessary, unlock by turning clockwise;
- the magnetic safety sensors of the covers and side windows;
- the security locks are, *in** **fact,** *locked;

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-06-52-11-84-PM.png?width=40&name=image-png-Jan-31-2022-06-52-11-84-PM.png) ATTENTION:** **Any** **maintenance** **work** **or** **changing** **of** **tools** **etc., that requires** **the machine** **to be operated** **with covers** **open, must** **only** **be** **carried** **out** **by** **trained** **and** **competent** **personnel** **and** **must** **be** **completed** **as** **quickly** **as** **possible** **before** **the** **covers** **are** **closed** **and** **full** **safety** **status** **is** **restored.**

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-06-52-11-84-PM.png?width=40&name=image-png-Jan-31-2022-06-52-11-84-PM.png) ATTENTION: All** **switch** **boxes,** **covers** **and** **guards** **must** **be closed before** **attempting to use** **the machine** **and** **must remain closed during use.**

It is strictly forbidden to operate the machine with any safety switches or other safety devices defeated or altered in any way. All these devices are fitted to protect the safety of the operator and other personnel. It is recommended that all such devices are checked and tested regularly to confirm that they are all operating correctly.

Each machine operator should be familiarized with all the safety features and devices associated with this machine.

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-08-39-20-20-PM.png?width=60&name=image-png-Jan-31-2022-08-39-20-20-PM.png) IT** **IS** **STRICTLY** **FORBIDDEN** **to** **remove** **any** **covers** **or** **guards** **while** **the machine** **is** **in operation.**

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-08-39-33-67-PM.png?width=60&name=image-png-Jan-31-2022-08-39-33-67-PM.png) IT** **IS** **STRONGLY** **RECOMMENDED** **TO** **attach** **and** **close** **ALL** **covers** **and guards** **designed** **for the machine.**

In the area around the machine, and up to 1.5m, all obstacles must be removed and the area must be clean and appropriately lit. Particular care should be taken when Fork Lift Trucks are fetching and removing materials and cartons.

The area in close vicinity to the machine should be clean and cleared of impurities such as oil, dust and dirt in order to reduce to the minimum the risk of a slip, trip or fall.

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-08-39-53-52-PM.png?width=60&name=image-png-Jan-31-2022-08-39-53-52-PM.png) ATTENTION:** **When** **the** **machine** **is** **in** **operation** **the** **area** **surrounding** **the** **machine** **should** **not** **be** **blocked** **as** **it** **may** **cause a** **slip,** **trip or fall.**

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-08-40-14-08-PM.png?width=60&name=image-png-Jan-31-2022-08-40-14-08-PM.png) UNDER** **NO** **CIRCUMSTANCES** **should** **any** **oil,** **solvents** **or** **other** **caustic** **or toxic** **liquids** **be** **poured out** **in the** **close** **vicinity** **to** **the machine.**

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-08-40-32-68-PM.png?width=60&name=image-png-Jan-31-2022-08-40-32-68-PM.png) IT** **IS** **THEREFORE** **ORDERED** **to** **keep** **the** **floor** **around** **the machine clean** **and** **clear.**

The machine controls, indicators, flexible conductors, pipes or shafts should not be used as handles. Any unintentional displacement of these machine parts may cause accidental and unintentional activation or changes to the machine working parameters and, in extreme situations, may lead to the machine failure or break- down.

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-08-40-51-18-PM.png?width=60&name=image-png-Jan-31-2022-08-40-51-18-PM.png) IT** **IS** **ESSENTIAL** **that** **any** **accident** **involving** **the** **operator,** **or any** **machine** **failure,** **should** **be** **promptly** **reported** **to** **the management.**

The qualified machine operators should be equipped with the regular working clothing, protective gloves and anti-slip, safety footwear.

Since the basic risks to the machine operators are moving rollers, wheels and shafts, the machine should not be operated by personnel wearing loose clothing or long and loose hair.

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-08-49-53-09-PM.png?width=60&name=image-png-Jan-31-2022-08-49-53-09-PM.png)IT** **IS** **ESSENTIAL** **to** **wear** **the** **suitable** **working** **clothing reducing** **to** **the** **minimum** **the** **possibility** **of** **being** **snagged** **or pulled into** **the machine.**

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-08-50-05-42-PM.png?width=60&name=image-png-Jan-31-2022-08-50-05-42-PM.png)IT** **IS** **ESSENTIAL** **to** **wear** **protective** **gloves** **while** **operating** **the machine and** **handling cardboard.**

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-08-50-18-49-PM.png?width=60&name=image-png-Jan-31-2022-08-50-18-49-PM.png) IT IS** **ESSENTIAL to** **wear** **anti-slip working footwear.**

**Hearing protection must be** **worn** **in this** **area!**

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-08-50-51-14-PM.png?width=60&name=image-png-Jan-31-2022-08-50-51-14-PM.png) IT IS** **ESSENTIAL to** **secure** **the operator’s** **hair** **in** **such** **a** **way** **to reduce** **to** **the** **minimum** **the** **risk** **of** **being** **snagged** **or** **pulled** **into the machine.**

**Controls and Indicators Available for Operator**

In the machine presented, all handling elements are located directly on its construction body, or on the control panel. Before using the machine, all personnel operating the machine should familiarize themselves with the location of these elements and the functions they control.

The handling and control elements of the machine which are available to the operator include:

![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Feb-01-2022-01-16-47-50-PM.png?width=300&name=image-png-Feb-01-2022-01-16-47-50-PM.png)   ![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Feb-07-2022-06-00-12-03-PM.png?width=400&name=image-png-Feb-07-2022-06-00-12-03-PM.png)   ![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Feb-01-2022-01-23-03-03-PM.png?width=300&name=image-png-Feb-01-2022-01-23-03-03-PM.png)

Fig.5. MAIN SWITCH                                                            Fig.6. CONTROL PANEL                                                                               Fig. 7 COMPRESSED AIR TERMINAL

1. **MAIN** **SWITCH** - the switch installed on the switch box doors (Fig.5), is designed to switch the electrical supply on and off. When it is turned to the 1 position it means that the machine is ON, when it is turned to the 0 position, it means that the machine is switched OFF.
2. **HMI** **panel** – a touch-sensitive screen which can be found on the control panel (Fig.6), it is designed to programming and control the machine. 
3. **START** – This green button, when lit, indicates that the machine is ready for work (Fig.6)
4. **RESET** – a blue button used to restart the control system and the machine’s safety system and alarms after an error (Fig.6).
5. **EMERGENCY** **STOP** - a mushroom-headed button for the immediate shutdown of the entire machine, in the event of any failure or accident. Buttons are located on the operator's panel (Fig.6) and to the rear and side of the machine.
6. Compressed air terminal (Fig.7);
7. The manually operated compressed air shut-off valve (in order to open the valve - turn it to the left and set to ON position; a turn to the right - the OFF position - the valve is closed);

**Positioning of Right Guide and Input Stops**

**ADJUSTING** **THE** **POSITION OF** **THE** **RIGHT** **LIMITER AND** **THE** **ENTRY** **BUMPERS**

***![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-06-52-11-84-PM.png?width=40&name=image-png-Jan-31-2022-06-52-11-84-PM.png) ATTENTION!**** ****Regulation**** ****should**** ****be**** ****conducted**** ****after**** ****selection**** ****of style,**** ****entering**** ****the**** ****cardboard**** ****dimensions**** ****and**** ****automatic**** ****setting of**** ****left**** ****guide.***

![Screen Shot 2022-02-01 at 8.26.32 AM](https://www.weldmaster.com/hs-fs/hubfs/Screen%20Shot%202022-02-01%20at%208.26.32%20AM.png?width=346&name=Screen%20Shot%202022-02-01%20at%208.26.32%20AM.png)    ![Screen Shot 2022-02-01 at 8.39.24 AM](https://www.weldmaster.com/hs-fs/hubfs/Screen%20Shot%202022-02-01%20at%208.39.24%20AM.png?width=257&name=Screen%20Shot%202022-02-01%20at%208.39.24%20AM.png)    ![Screen Shot 2022-02-01 at 8.39.38 AM](https://www.weldmaster.com/hs-fs/hubfs/Screen%20Shot%202022-02-01%20at%208.39.38%20AM.png?width=380&name=Screen%20Shot%202022-02-01%20at%208.39.38%20AM.png)![Screen Shot 2022-02-01 at 8.42.11 AM](https://www.weldmaster.com/hs-fs/hubfs/Screen%20Shot%202022-02-01%20at%208.42.11%20AM.png?width=383&name=Screen%20Shot%202022-02-01%20at%208.42.11%20AM.png)  ![Screen Shot 2022-02-01 at 8.43.53 AM](https://www.weldmaster.com/hs-fs/hubfs/Screen%20Shot%202022-02-01%20at%208.43.53%20AM.png?width=385&name=Screen%20Shot%202022-02-01%20at%208.43.53%20AM.png) ![Screen Shot 2022-02-01 at 8.44.40 AM](https://www.weldmaster.com/hs-fs/hubfs/Screen%20Shot%202022-02-01%20at%208.44.40%20AM.png?width=363&name=Screen%20Shot%202022-02-01%20at%208.44.40%20AM.png)  ![Screen Shot 2022-02-01 at 8.47.05 AM](https://www.weldmaster.com/hs-fs/hubfs/Screen%20Shot%202022-02-01%20at%208.47.05%20AM.png?width=381&name=Screen%20Shot%202022-02-01%20at%208.47.05%20AM.png)

1. Place the blank on the table
2. Undo handles of the input stops (Fig.9).
3. Lift up the input stops gently and slide apart two of them towards the ends of board and the third one should be placed in the center and over the roller (Fig.11).
4. Tighten up the orange handles of the input stops (Fig.9).
5. Using the knob (Fig. 10) set the gap under each bumper so that it is possible to insert one carton into it; ensure, however, that it is not possible to insert two cartons (Fig.12).
6. Set the right stop with the help of the hand grip (Fig.13) so that it almost sticks to the mat; leave 1/16” of slack so that the mats do not jam between the stops (Fig.14).

**Connection to a Power Source**

1. Check the area around the machine. It is designed to work in a clean and neat environment without any waste or obstacles that could adversely influence on its regular working activity.
2. Prepare the corrugated blanks, ready for production.
3. If required by the production cycle provided by the user, place containers for waste and ready-printed cartons in a suitable place, near the machine.
4. Check that all covers and guards are in place and that all doors are closed – it is strictly forbidden to perform work with open covers or missing guards as this will trigger the proximity sensors and prevent the machine from working.
5. Check that the **EMERGENCY** **STOP** **push-button** on the control panel is in the correct position. In order to reset it turn the mushroom-headed push- button clockwise.
6. Connect the electrical power supply to the machine (put the plug into the power supply socket and/or switch on) and the compressed air system by connecting the air hose to the terminal and switching on the compressor.
7. Check that the pneumatic supply is between 85psi/6bar and 110psi/8bar.
8. Turn the **MAIN** **SWITCH** installed in the machine side casing, to the **1** **/** **ON **position.
9. PC Panel (HMI) with Windows system will start-up.
10. Due to standard procedure when the machine is switched on, an error message such as “Safety system not ready - press RESET button” should be found on the HMI touch panel. In order to put the machine in motion press RESET button. As a result, the test of safety system and the drives shall be put into operation. When the START button flashes green, it means that the machine enters a stand-by mode and it is ready for work.
11. If all procedures end up successfully, the machine is ready for work – the main window should be displayed on the HMI panel.

![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Feb-07-2022-06-10-33-99-PM.png?width=500&name=image-png-Feb-07-2022-06-10-33-99-PM.png)

Fig. 15. Boxmat interface Inteligo start-up

![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Feb-07-2022-06-13-52-27-PM.png?width=500&name=image-png-Feb-07-2022-06-13-52-27-PM.png)

Fig. 16. Safety system not ready

![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Feb-07-2022-06-15-02-25-PM.png?width=500&name=image-png-Feb-07-2022-06-15-02-25-PM.png)

Fig. 17. Boxmat PRO main screen 

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-06-52-11-84-PM.png?width=30&name=image-png-Jan-31-2022-06-52-11-84-PM.png) ATTENTION:** **Covers** **must** **always** **be** **closed** **or** **the** **machine will not work.**

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Feb-01-2022-02-13-03-23-PM.png?width=40&name=image-png-Feb-01-2022-02-13-03-23-PM.png) ATTENTION: the EMERGENCY STOP button is designed to be pressed at any time especially when an emergency shut- down is promptly needed*.***

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Jan-31-2022-06-52-11-84-PM.png?width=30&name=image-png-Jan-31-2022-06-52-11-84-PM.png) ATTENTION!** **In** **case** **the** **error** **message** **can** **still** **be** **seen** **on the** **display** **after** **pressing** **the** **START** **button,** **go** **to** **ALARMS, ERROR** **MESSAGES** **and** **FAILURES** **shown** **in** **the** **technical documentation.**

**Disconnection**

The following switch-off procedure should always be implemented when production is completed:

1. Go to main screen
2. Shut down the Boxmat interface - choose "Exit" icon
3. Shut down the Windows system
4. After a proper Windows shut down, turn the **MAIN SWITCH** to the position **0-OFF** -- this means that the machine is switched off.
5. Clear the working environment around the machine.
6. If the machine is being shut down for a longer period - i.e. the weekend - The electrical power supply and the compressed air should be disconnected.

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Feb-07-2022-06-20-36-83-PM.png?width=40&name=image-png-Feb-07-2022-06-20-36-83-PM.png) ATTENTION!** **Do** **not** **turn** **off** **the** **machine** **during** **Windows shut** **down ! This can** **damage** **HMI PC !**

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Feb-07-2022-06-21-00-81-PM.png?width=500&name=image-png-Feb-07-2022-06-21-00-81-PM.png)**

Fig. 18. Exit from Boxmat interface

![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Feb-07-2022-06-21-42-36-PM.png?width=500&name=image-png-Feb-07-2022-06-21-42-36-PM.png)

Fig. 19. Shut down Windows

**7.0 Description of HMI Panel Screen**

**Home - Choice of Box Design**

On the main screen, are the basic formats of the FEFCO styles available. First, select the style or select ‘Other’ if a Free Style box is to be designed.

![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Feb-07-2022-06-22-37-38-PM.png?width=400&name=image-png-Feb-07-2022-06-22-37-38-PM.png)

Fig. 20 BASIC FORMATS screen

1. SETTINGS - the button opens a SETTINGS screen (page 50). On this screen, three further screens can be selected: 
     - Manual Movement - options available on the Manual Movements screens which allow all moving parts, available in the machine, to be moved manually.
     - Service - options available in the Service screens contain statistical information on the machine’s operation and advanced parameters of the machine's operation.
2. MENU - the button opens a screen showing the following features: LOGGING IN, RECIPES, STATISTIC and LANGUAGE settings.
3. ![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Feb-07-2022-06-26-40-78-PM.png?width=40&name=image-png-Feb-07-2022-06-26-40-78-PM.png) Choose this button to change language of the interface.
4. QUEUE JOB - the button opens screen with "Queue job" work mode.
5. FEFCO - the button opens screen with saved FEFCO recipes.
6. Box wizard - the button opens screen with saved recipes prepared in Box Wizard.
7. SLOTTED-TYPE BOXES (flap boxes) - the button opens a screen containing templates for flap boxes in FEFCO styles (Fig. 21).

![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Feb-07-2022-06-30-01-01-PM.png?width=400&name=image-png-Feb-07-2022-06-30-01-01-PM.png)

Fig. 21. The Screen displays Flap Box style templates FEFCO 2xx (1/2)

8. Telescopic-type boxes - the button opens a screen showing templates for telescopic boxes in the FEFCO styles (Fig. 23).

 

![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Feb-07-2022-06-33-50-99-PM.png?width=400&name=image-png-Feb-07-2022-06-33-50-99-PM.png)

 

9. Folder-type boxes and trays - the button opens a screen displaying templates for the folding boxes and trays FEFCO styles (Fig. 24)

![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Feb-07-2022-06-53-07-76-PM.png?width=400&name=image-png-Feb-07-2022-06-53-07-76-PM.png)

Fig. 23. The screen displays templates for the folding boxes and trays in the FEFCO 4xx styles

 

10. Slide-type boxes - the button opens a screen displaying templates for slip-in boxes in FEFCO styles (Fig. 24).

![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Feb-07-2022-06-55-24-34-PM.png?width=400&name=image-png-Feb-07-2022-06-55-24-34-PM.png)

Fig. 24. The screen displays templates for slip-in boxes in the FEFCO 5xx styles

 

7. Box Wizard - the button opens a screen showing Freestyle main screen (Fig. 25).

 

![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Feb-07-2022-06-58-17-41-PM.png?width=400&name=image-png-Feb-07-2022-06-58-17-41-PM.png)

Fig. 25. Free style main screen containing entrance to Box Wizard creator.

 

12. Cutting – the button opens the Sheet Cutting configuration screen.

![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Feb-07-2022-06-59-54-55-PM.png?width=400&name=image-png-Feb-07-2022-06-59-54-55-PM.png)

Fig. 26 Sheet cutting mode

 

**Settings Screens**

Pressing the SETTINGS button (1) in the main screen, will open the Settings screens. 

Options available in Settings allows to manual movements of each tool installed in the machine, setup machine parameters like tools orientation, etc. 

With Service access level it is possible to change service parameters - advanced parameters of the machine's operation. 

![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Feb-07-2022-07-05-58-32-PM.png?width=500&name=image-png-Feb-07-2022-07-05-58-32-PM.png)

Fig. 27. Manual Movements screen (1/3) 

13. Scoring beam ![Screen Shot 2022-02-01 at 11.38.26 AM](https://www.weldmaster.com/hs-fs/hubfs/Screen%20Shot%202022-02-01%20at%2011.38.26%20AM.png?width=27&name=Screen%20Shot%202022-02-01%20at%2011.38.26%20AM.png) buttons for the slow movement of the slotting/scoring beam. Continues while button is pushed:

- ![Screen Shot 2022-02-01 at 11.41.56 AM](https://www.weldmaster.com/hs-fs/hubfs/Screen%20Shot%202022-02-01%20at%2011.41.56%20AM.png?width=23&name=Screen%20Shot%202022-02-01%20at%2011.41.56%20AM.png) moves the scoring beam upwards
- ![Screen Shot 2022-02-01 at 11.41.19 AM](https://www.weldmaster.com/hs-fs/hubfs/Screen%20Shot%202022-02-01%20at%2011.41.19%20AM.png?width=24&name=Screen%20Shot%202022-02-01%20at%2011.41.19%20AM.png) moves the scoring beam downwards;

![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Feb-02-2022-05-30-40-10-PM.png?width=50&name=image-png-Feb-02-2022-05-30-40-10-PM.png)***When the Up Arrow button displays yellow, it indicates that the scoring/slotting beam is in the top position ready for starting.***

 

14. BASE - the button sets the scoring beam with slotting knives in the top position for starting. Reference mode.

 15. FAST CUT - the button starts one full cycle of the scoring/slotting beam at setup speed

 

16. Score depth across – beam scoring depth in %,

17. Score depth along - air pressure for scoring wheels

18. **+ - **these buttons change the depth of the scores along the box by adjusting the pressure on the wheels/rolls. Pressing the button changes the pressure setting by 0.1 bar.: • + increases the pressure; 

- + increases the pressure;
- - decreases the pressure

***![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Feb-02-2022-05-30-40-10-PM.png?width=50&name=image-png-Feb-02-2022-05-30-40-10-PM.png)It is possible to set pressure within the range 0 to 3 bar.***

 

***![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Feb-02-2022-05-30-40-10-PM.png?width=50&name=image-png-Feb-02-2022-05-30-40-10-PM.png)***

***The pressure can never reach a value greater than the supply pressure to the machine.***

 

19. The field displaying the actual pressure applied to the scoring rolls.

20. The field displaying the set pressure applied to the scoring rolls. In this field, it is possible to enter the pressure value. By pressing the Enter button on the keyboard, the pressure will be updated

21. ![Screen Shot 2022-02-01 at 11.48.03 AM](https://www.weldmaster.com/hs-fs/hubfs/Screen%20Shot%202022-02-01%20at%2011.48.03%20AM.png?width=58&name=Screen%20Shot%202022-02-01%20at%2011.48.03%20AM.png) these buttons change the position of the slotting knives. Press and hold to move:

- ![Screen Shot 2022-02-01 at 11.48.15 AM](https://www.weldmaster.com/hs-fs/hubfs/Screen%20Shot%202022-02-01%20at%2011.48.15%20AM.png?width=29&name=Screen%20Shot%202022-02-01%20at%2011.48.15%20AM.png) the slotting knives move apart slowly.
- ![Screen Shot 2022-02-01 at 11.48.24 AM](https://www.weldmaster.com/hs-fs/hubfs/Screen%20Shot%202022-02-01%20at%2011.48.24%20AM.png?width=30&name=Screen%20Shot%202022-02-01%20at%2011.48.24%20AM.png) the slotting knives move closer slowly.

![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Feb-02-2022-05-30-40-10-PM.png?width=50&name=image-png-Feb-02-2022-05-30-40-10-PM.png)

***The position of the slotting knives is measured as the distance from the point of the left knife to the point of the right knife. The knives move evenly toward or away from the center of the machine. Spacing of the blades can range from 2 1/2” to 78 1/2“.***

![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Feb-02-2022-05-30-40-10-PM.png?width=50&name=image-png-Feb-02-2022-05-30-40-10-PM.png)

 ***When one of the buttons displays a yellow arrow, it indicates that the slotting knives have travelled as far as possible.***

 

22. Actual - the field displays the current distance between the slotting knives.

23. Set field - enter the distance at which the slotting knives should be spaced.

24. Set button - starts the slotting knives' movement to a position as entered in the Set field (19).

25. Calibration button – opens a window to enter the actual measurement between the knives. This will update the ‘Actual’ field.

![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Feb-02-2022-05-30-40-10-PM.png?width=50&name=image-png-Feb-02-2022-05-30-40-10-PM.png)

***Opening of the calibration window is only possible after entering Password 7415***

 

26. STOP – the button stops slotting knives movement

27. Board Pass Motion ![Screen Shot 2022-02-01 at 11.38.26 AM](https://www.weldmaster.com/hs-fs/hubfs/Screen%20Shot%202022-02-01%20at%2011.38.26%20AM.png?width=27&name=Screen%20Shot%202022-02-01%20at%2011.38.26%20AM.png) Press and hold to move the corrugated sheet in or out of the machine. Press ![Screen Shot 2022-02-01 at 11.41.56 AM](https://www.weldmaster.com/hs-fs/hubfs/Screen%20Shot%202022-02-01%20at%2011.41.56%20AM.png?width=16&name=Screen%20Shot%202022-02-01%20at%2011.41.56%20AM.png) for forward and ![Screen Shot 2022-02-01 at 11.41.19 AM](https://www.weldmaster.com/hs-fs/hubfs/Screen%20Shot%202022-02-01%20at%2011.41.19%20AM.png?width=18&name=Screen%20Shot%202022-02-01%20at%2011.41.19%20AM.png) for reverse.

28. Board Guide ![Screen Shot 2022-02-01 at 11.48.15 AM](https://www.weldmaster.com/hs-fs/hubfs/Screen%20Shot%202022-02-01%20at%2011.48.15%20AM.png?width=29&name=Screen%20Shot%202022-02-01%20at%2011.48.15%20AM.png) Press and hold these buttons to change the position of the left, automatic, board guide.

![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Feb-02-2022-05-30-40-10-PM.png?width=50&name=image-png-Feb-02-2022-05-30-40-10-PM.png)

***The position of the left guide is measured as the distance from the inner wall of the guide to the center of the machine. It is possible to set the guide within the range 1 3/4” to 47”.***

![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Feb-02-2022-05-30-40-10-PM.png?width=50&name=image-png-Feb-02-2022-05-30-40-10-PM.png)

***When one of the buttons displays a yellow arrow, it indicates that the left guide is in the extreme position.***

 

29. Actual Position - the field displays the current position of the board guide.

30. Set - the field in which it is possible to enter the position at which the left board guide is to be set.

31. Set - this button moves the left guide to the position in the ‘Set’ field. (26).

32. Calibration button – opens a window to enter the actual distance from the center of the machine to the left guide. This will update the ‘Actual’ field (25).

![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Feb-02-2022-05-30-40-10-PM.png?width=50&name=image-png-Feb-02-2022-05-30-40-10-PM.png)

**Opening of the calibration window is only possible at the operator level or higher.**

 

33. STOP – the button stops the left guide movement

34. Feeding Wheels: ![Screen Shot 2022-02-01 at 11.58.17 AM](https://www.weldmaster.com/hs-fs/hubfs/Screen%20Shot%202022-02-01%20at%2011.58.17%20AM.png?width=24&name=Screen%20Shot%202022-02-01%20at%2011.58.17%20AM.png) - these buttons are used to start or stop the feed rollers.

35. ![Screen Shot 2022-02-01 at 11.59.25 AM](https://www.weldmaster.com/hs-fs/hubfs/Screen%20Shot%202022-02-01%20at%2011.59.25%20AM.png?width=35&height=37&name=Screen%20Shot%202022-02-01%20at%2011.59.25%20AM.png) this button returns to the previous screen (Fig. 24).

36. ![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Feb-07-2022-07-23-08-62-PM.png?width=30&name=image-png-Feb-07-2022-07-23-08-62-PM.png)  this button leads to the next screen (Fig.26).

![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Feb-07-2022-07-38-31-33-PM.png?width=500&name=image-png-Feb-07-2022-07-38-31-33-PM.png)

Fig. 28. Manual Movements Screen (2/3)

37. REFERENCING - this button moves the tool holder to his initial position.

****![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Feb-02-2022-05-30-40-10-PM.png?width=50&name=image-png-Feb-02-2022-05-30-40-10-PM.png)*When** **REFERENCING** **procedure** **is** **active** **backlight** **of** **the** **push button** **is** **on*.**

 

38. SCANNING - this button moves the scanner (tool holder) over the tools to define their actual positions and to check their quantities.

****![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Feb-02-2022-05-30-40-10-PM.png?width=50&name=image-png-Feb-02-2022-05-30-40-10-PM.png)*When** **SCANNING** **procedure** **is** **active** **backlight** **of** **the** **push** **button is** **on*.**

 

39. SETUP TOOLS - this button moves the longitudinal cutting knives and scoring wheels to their pre-set positions as entered in the setup fields.

****![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Feb-02-2022-05-30-40-10-PM.png?width=50&name=image-png-Feb-02-2022-05-30-40-10-PM.png)*When** **SETUP** **procedure** **is** **active** **backlight** **of** **the** **push** **button** **is** **on*.**

 

40. EXCHANGE POSITIONS – this button setting values in target positions which are optimal for tool exchange  
41. TOOLS CHANGE – service mode for tools change

42. Actual position - the fields display the actual position of each longitudinal knife/score.

****![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Feb-02-2022-05-30-40-10-PM.png?width=50&name=image-png-Feb-02-2022-05-30-40-10-PM.png)****

*** The position of each lengthwise cutting knife/scoring wheel is measured as the distance from the blade to the center of the machine. It is possible to set the knives within the range of 0" to 47". It is possible to set the scoring rolls within the range of 1" to 47".***

43. Target Position - Fields displaying the pre-determined position of each lengthwise knife. In these fields, it is possible to enter the position at which each knife is to be set from the center.

***![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Feb-02-2022-05-30-40-10-PM.png?width=50&name=image-png-Feb-02-2022-05-30-40-10-PM.png)The knives should be spaced in the same order as presented in the graphics, otherwise the message "NOT POSSIBLE TO SET UP ALONG KNIVES [KNIFE NUMBER ]” will be displayed.***

44. Up/down - pressing on this button ![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Feb-07-2022-09-13-08-08-PM.png?width=30&name=image-png-Feb-07-2022-09-13-08-08-PM.png)   will lift or lower the corresponding longitudinal tool.

![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Feb-07-2022-09-13-33-31-PM.png?width=600&name=image-png-Feb-07-2022-09-13-33-31-PM.png)

 45. Longitudinal tools beam -

1. 1. – tools gripper . Pressing on it will show pop-up GRIPPER
     2. – longitudinal knife. Pressing on it will show pop-up KNIFE
     3. – longitudinal score. Pressing on it will show pop-up SCORE

46. Pop-up GRIPPER

![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Feb-07-2022-09-14-48-41-PM.png?width=300&name=image-png-Feb-07-2022-09-14-48-41-PM.png)

Fig. 30. Pop-up GRIPPER

47. ![Screen Shot 2022-02-01 at 11.48.15 AM](https://www.weldmaster.com/hs-fs/hubfs/Screen%20Shot%202022-02-01%20at%2011.48.15%20AM.png?width=29&name=Screen%20Shot%202022-02-01%20at%2011.48.15%20AM.png) these buttons change the position of the tool gripper, manual movement of the gripper

48. ![Screen Shot 2022-02-01 at 11.38.26 AM](https://www.weldmaster.com/hs-fs/hubfs/Screen%20Shot%202022-02-01%20at%2011.38.26%20AM.png?width=27&name=Screen%20Shot%202022-02-01%20at%2011.38.26%20AM.png) these buttons lock or release the score rollers gripper pin:

- ![Screen Shot 2022-02-01 at 11.41.56 AM](https://www.weldmaster.com/hs-fs/hubfs/Screen%20Shot%202022-02-01%20at%2011.41.56%20AM.png?width=18&name=Screen%20Shot%202022-02-01%20at%2011.41.56%20AM.png) unlocks the gripper pin;
- ![Screen Shot 2022-02-01 at 11.41.19 AM](https://www.weldmaster.com/hs-fs/hubfs/Screen%20Shot%202022-02-01%20at%2011.41.19%20AM.png?width=18&name=Screen%20Shot%202022-02-01%20at%2011.41.19%20AM.png) locks the gripper pin.

49. ![Screen Shot 2022-02-01 at 11.38.26 AM](https://www.weldmaster.com/hs-fs/hubfs/Screen%20Shot%202022-02-01%20at%2011.38.26%20AM.png?width=27&name=Screen%20Shot%202022-02-01%20at%2011.38.26%20AM.png) these buttons lock or release the longitudinal knives gripper pin:

- ![Screen Shot 2022-02-01 at 11.41.56 AM](https://www.weldmaster.com/hs-fs/hubfs/Screen%20Shot%202022-02-01%20at%2011.41.56%20AM.png?width=18&name=Screen%20Shot%202022-02-01%20at%2011.41.56%20AM.png) unlocks the gripper pin;
- ![Screen Shot 2022-02-01 at 11.41.19 AM](https://www.weldmaster.com/hs-fs/hubfs/Screen%20Shot%202022-02-01%20at%2011.41.19%20AM.png?width=18&name=Screen%20Shot%202022-02-01%20at%2011.41.19%20AM.png) locks the gripper pin.

50. Score sensor – sensor on the side of the scoring rolls. Detects holder with scoring roll. 

51. Knife sensor – sensor on the side of the knives. Detects holder with knife. 

52. Pop-up KNIFE

![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Feb-07-2022-09-20-59-50-PM.png?width=300&name=image-png-Feb-07-2022-09-20-59-50-PM.png)

Fig.31. Pop-up KNIFE

53. Tool type - the currently installed knife type should be selected on the chosen holder. 

****![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Feb-02-2022-05-30-40-10-PM.png?width=50&name=image-png-Feb-02-2022-05-30-40-10-PM.png)****

***The operator must always confirm tool type change in this window. The selected tool type is highlighted in green.***

 

54. Tool orientation - the current orientation of the installed tool.

****![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Feb-02-2022-05-30-40-10-PM.png?width=50&name=image-png-Feb-02-2022-05-30-40-10-PM.png)*The selected tool orientation is highlighted in green.***

 

***The operator, after manually changing the *![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Feb-02-2022-05-30-40-10-PM.png?width=50&name=image-png-Feb-02-2022-05-30-40-10-PM.png)*orientation of the longitudinal knife on the machine, must also mark/make this change in this window.***

 

55. Brake - releases the brake of the selected tool holder. 

****![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Feb-02-2022-05-30-40-10-PM.png?width=50&name=image-png-Feb-02-2022-05-30-40-10-PM.png)*Each time the brake is released, scan the tools to find their current position.***

 

56. Pop-up SCORE

 

![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Feb-08-2022-01-17-46-83-PM.png?width=300&name=image-png-Feb-08-2022-01-17-46-83-PM.png)

Fig.32. Pop-up SCORE

57. Tool type - the currently installed scoring wheel type should be selected on the chosen holder.

***The operator must always confirm tool *![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Feb-02-2022-05-30-40-10-PM.png?width=50&name=image-png-Feb-02-2022-05-30-40-10-PM.png)*type change in this window. The selected tool type is highlighted in green.***

 

58. Tool orientation - the current orientation of the installed tool.

![Screen Shot 2022-02-08 at 8.22.30 AM](https://www.weldmaster.com/hs-fs/hubfs/Screen%20Shot%202022-02-08%20at%208.22.30%20AM.png?width=400&name=Screen%20Shot%202022-02-08%20at%208.22.30%20AM.png)

Fig. 33. An example of tool orientation on the basis of creasing rollers: A - to the left of the fixing as viewed from the front of the machine, B - to the right of the fixing as viewed from the front of the machine

****![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Feb-02-2022-05-30-40-10-PM.png?width=50&name=image-png-Feb-02-2022-05-30-40-10-PM.png)*The selected tool orientation is highlighted in green.***

 

***The operator, after manually changing the *![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Feb-02-2022-05-30-40-10-PM.png?width=50&name=image-png-Feb-02-2022-05-30-40-10-PM.png)*orientation of the longitudinal score on the machine, must also mark/make this change in this window.***

 

59. Brake - releases the brake of the selected tool holder. 

****![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Feb-02-2022-05-30-40-10-PM.png?width=50&name=image-png-Feb-02-2022-05-30-40-10-PM.png)*Each time the brake is released, scan the tools to find their current position.***

 

![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Feb-08-2022-01-41-37-28-PM.png?width=500&name=image-png-Feb-08-2022-01-41-37-28-PM.png)

Fig.34. Manual Movements screen (3/3)

60. ACROSS TOOL ![Screen Shot 2022-02-01 at 11.48.15 AM](https://www.weldmaster.com/hs-fs/hubfs/Screen%20Shot%202022-02-01%20at%2011.48.15%20AM.png?width=29&name=Screen%20Shot%202022-02-01%20at%2011.48.15%20AM.png) the buttons for the manual operation of the across cutting knife:

- ![Screen Shot 2022-02-03 at 8.12.48 AM](https://www.weldmaster.com/hs-fs/hubfs/Screen%20Shot%202022-02-03%20at%208.12.48%20AM.png?width=18&name=Screen%20Shot%202022-02-03%20at%208.12.48%20AM.png) moves the knife to the left;
- ![Screen Shot 2022-02-03 at 8.13.02 AM](https://www.weldmaster.com/hs-fs/hubfs/Screen%20Shot%202022-02-03%20at%208.13.02%20AM.png?width=18&name=Screen%20Shot%202022-02-03%20at%208.13.02%20AM.png) moves the knife to the right.

61. The graphic shows the transverse cutting knife. Pressing on the picture will lift or lower the knife. The lowering of the knife is indicated by a green "tick" ![Screen Shot 2022-02-02 at 12.27.44 PM](https://www.weldmaster.com/hs-fs/hubfs/Screen%20Shot%202022-02-02%20at%2012.27.44%20PM.png?width=18&name=Screen%20Shot%202022-02-02%20at%2012.27.44%20PM.png).

62. REFERENCING - this button moves the across cutting knife to the home position.

****![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Feb-02-2022-05-30-40-10-PM.png?width=50&name=image-png-Feb-02-2022-05-30-40-10-PM.png)*When** **REFERENCING** **procedure** **is** **active** **backlight** **of** **the** **push button is** **on*.**

 

63. Output Wheels - The graphic shows the non-crush roller. Pressing on the picture lifts or lowers all the exit rollers.

64.Printer module 1 (option):

- ![Screen Shot 2022-02-03 at 8.42.17 AM](https://www.weldmaster.com/hs-fs/hubfs/Screen%20Shot%202022-02-03%20at%208.42.17%20AM.png?width=18&name=Screen%20Shot%202022-02-03%20at%208.42.17%20AM.png) lift up/down the printer module 1.
- ![Screen Shot 2022-02-03 at 8.16.35 AM](https://www.weldmaster.com/hs-fs/hubfs/Screen%20Shot%202022-02-03%20at%208.16.35%20AM.png?width=18&name=Screen%20Shot%202022-02-03%20at%208.16.35%20AM.png) or ![Screen Shot 2022-02-03 at 8.16.46 AM](https://www.weldmaster.com/hs-fs/hubfs/Screen%20Shot%202022-02-03%20at%208.16.46%20AM.png?width=18&name=Screen%20Shot%202022-02-03%20at%208.16.46%20AM.png)indicates the position of printer module 1.

65. Printer module 2 (option):

- ![Screen Shot 2022-02-03 at 8.42.17 AM](https://www.weldmaster.com/hs-fs/hubfs/Screen%20Shot%202022-02-03%20at%208.42.17%20AM.png?width=18&name=Screen%20Shot%202022-02-03%20at%208.42.17%20AM.png) lift up/down the printer module 2.
- ![Screen Shot 2022-02-03 at 8.16.35 AM](https://www.weldmaster.com/hs-fs/hubfs/Screen%20Shot%202022-02-03%20at%208.16.35%20AM.png?width=18&name=Screen%20Shot%202022-02-03%20at%208.16.35%20AM.png) or ![Screen Shot 2022-02-03 at 8.16.46 AM](https://www.weldmaster.com/hs-fs/hubfs/Screen%20Shot%202022-02-03%20at%208.16.46%20AM.png?width=18&name=Screen%20Shot%202022-02-03%20at%208.16.46%20AM.png)indicates the position of printer module 2.

66. GLUE HEADS - the graphics shows two the gluing heads. Pressing on a selected graphic will open this glue head valve.

![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Feb-08-2022-01-56-24-07-PM.png?width=400&name=image-png-Feb-08-2022-01-56-24-07-PM.png)

Fig.35. The setting of gluing line (option)

67. Gluing line 1 – Set – Opening time of the gluing head for the gluing line 1 (Fig.35) (option).

68. Gluing line 1 – MAX – Cycle time of the gluing head for the gluing line 1 (Fig.35) (option).

69. Gluing line 2 – Set - Opening time of the gluing head for the gluing line 2 (Fig.35) (option).

70. Gluing line 2 – MAX – Cycle time of the gluing head for the gluing line 2 (Fig.35) (option).

![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Feb-08-2022-01-58-27-89-PM.png?width=500&name=image-png-Feb-08-2022-01-58-27-89-PM.png)

Fig. 36. The Machine Parameters’ screen

71. Correction of the 1st pass – this parameter will affect the length of the first panel of a box. If any maintenance has taken place, this parameter may need to be changed.

72. Starting position of the beam above the board – distance between board surface and slotting knife as a start point for beam move

73. Slotting knives length – length of slotting knives mounted on the machine

74. Orientation of the board – rapid or smooth board passing in cycle

75.Circumference of measuring wheel 1 and 2 - the exact circumference of the measuring wheels.

76. Board move – ![Screen Shot 2022-02-01 at 11.38.26 AM](https://www.weldmaster.com/hs-fs/hubfs/Screen%20Shot%202022-02-01%20at%2011.38.26%20AM.png?width=27&name=Screen%20Shot%202022-02-01%20at%2011.38.26%20AM.png) Press and hold to move the corrugated sheet in or out of the machine. Press ![Screen Shot 2022-02-01 at 11.41.56 AM](https://www.weldmaster.com/hs-fs/hubfs/Screen%20Shot%202022-02-01%20at%2011.41.56%20AM.png?width=18&name=Screen%20Shot%202022-02-01%20at%2011.41.56%20AM.png) for forward and ![Screen Shot 2022-02-01 at 11.41.19 AM](https://www.weldmaster.com/hs-fs/hubfs/Screen%20Shot%202022-02-01%20at%2011.41.19%20AM.png?width=18&name=Screen%20Shot%202022-02-01%20at%2011.41.19%20AM.png) for reverse.

77. Set – the distance the board will travel after pressing the Encoder 1 or Encoder 2 buttons, measured by corresponding measuring wheel 1 or 2

78. V – speed parameters – this button open the pop-up Speed.

79. Pop-up Speed

![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Feb-08-2022-02-19-45-91-PM.png?width=300&name=image-png-Feb-08-2022-02-19-45-91-PM.png)

Fig.37. Pop-up Speed

80. Feed rate – speed of the board movement in the cycle.

81. Across knife – speed of the across cutting knife in the cycle.

82. Scoring beam – speed of the slotting/scoring beam in the cycle.

83. Across tool – ![Screen Shot 2022-02-01 at 11.48.15 AM](https://www.weldmaster.com/hs-fs/hubfs/Screen%20Shot%202022-02-01%20at%2011.48.15%20AM.png?width=29&name=Screen%20Shot%202022-02-01%20at%2011.48.15%20AM.png) the buttons for the manual operation of the across cutting knife:

- ![Screen Shot 2022-02-03 at 8.12.48 AM](https://www.weldmaster.com/hs-fs/hubfs/Screen%20Shot%202022-02-03%20at%208.12.48%20AM.png?width=18&name=Screen%20Shot%202022-02-03%20at%208.12.48%20AM.png) moves the knife to the left;
- ![Screen Shot 2022-02-03 at 8.13.02 AM](https://www.weldmaster.com/hs-fs/hubfs/Screen%20Shot%202022-02-03%20at%208.13.02%20AM.png?width=18&name=Screen%20Shot%202022-02-03%20at%208.13.02%20AM.png) moves the knife to the right.

84. The graphic shows the transverse cutting knife. Pressing on the picture will lift or lower the knife. The lowering of the knife is indicated by a green "tick" ![Screen Shot 2022-02-02 at 12.27.44 PM](https://www.weldmaster.com/hs-fs/hubfs/Screen%20Shot%202022-02-02%20at%2012.27.44%20PM.png?width=18&name=Screen%20Shot%202022-02-02%20at%2012.27.44%20PM.png).

85. Speed of across movement for the gluing – speed of the transversal tool movement for putting the glue in the cycle

86. External queue – enables the working with “Job Queue”

87. Encoder 1 / 2 – activates close loop control to set parameters for measuring wheel 1/2

![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Feb-08-2022-02-27-08-93-PM.png?width=500&name=image-png-Feb-08-2022-02-27-08-93-PM.png)

Fig. 38. Counters and Alarms history

 88. Total number of slot cuts – the number of cuts made by the slotting beam since machine inception.

89. Service number of slotting knives cuts – the number of cuts made by the slotting beam since the last service.

90. Total number of cycles – the number of automatic work cycles since machine inception.

91. Total number of km – the number of kilometers of the corrugated measured by the encoders since machine inception.

92. Active alarms – displays active alarms / messages

93. Alarm history – the record of alarms / messages

**‘FEFCO’ STYLE SCREENS - DESCRIPTION ON THE BASIS OF STANDARD STYLE 201 **

Following are the features available in the configuration screens for the FEFCO 0201 standard style. 

![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Feb-08-2022-02-30-49-72-PM.png?width=500&name=image-png-Feb-08-2022-02-30-49-72-PM.png)

Fig. 39. Main FEFCO 201 STANDARD style set-up screen

94. 0201 - the FEFCO style selected.

95. ![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Feb-08-2022-02-32-30-44-PM.png?width=40&name=image-png-Feb-08-2022-02-32-30-44-PM.png) - saves the current box into the machine's memory with the name written in the RECIPE NAME field. Operation confirmed with message “Recipe added.”

96. Load to Freestyle – copies the current machine setting to the Freestyle

97. Add to Queue – adds the currently set box to the Job Queue. Operation confirmed with message “Order was added.”

98. Box dimensions – internal dimensions of the required box

99. Thickness – cardboard flute type

100. Score depth settings – Across – beam scoring depth in %:

***The setting of the depth of the across score *![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Feb-02-2022-05-30-40-10-PM.png?width=50&name=image-png-Feb-02-2022-05-30-40-10-PM.png)*should be in range 0% to 100%:***

- ***value 0% - without scoring between the slots;***
- ***value 100% - max scoring depth between the slots;***

101. Score depth settings – Along – **+** and **-** buttons for adjusting the depth of along scores on the board:

***The setting for depth of the scores should *![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Feb-02-2022-05-30-40-10-PM.png?width=50&name=image-png-Feb-02-2022-05-30-40-10-PM.png)*be selected according to preference***

 

102. Input board dimensions – Length and Width of the input sheet

103. Calculated board dimensions – Length and Width of the required board

104. Target Qty - the number of boxes to be made.

105. Actual Qty – the number of cartons already made. Next to it, there is a RESET button used to reset the count. To modify quantity done counter, use PLUS/MINUS buttons.

***After completing the required number of *![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Feb-02-2022-05-30-40-10-PM.png?width=50&name=image-png-Feb-02-2022-05-30-40-10-PM.png)*cardboard boxes, the machine will stop. To continue production, the RESET button should be pressed, otherwise it will not be possible to start a new cycle.***

106. Multiproduction – Max – shows the number of current boxes that can be produced from the length of the current sheet.

107. Multiproduction – Target – enter the number of boxes required from the sheet. The value may be lower or equal to the MAX value.

108. Printing – this button opens a pop-up to set parameters of printing (option).

109. Gluing – this button opens a pop-up to a set parameters of gluing (option).

110. Pop-up Gluing

![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Feb-08-2022-02-52-57-30-PM.png?width=400&name=image-png-Feb-08-2022-02-52-57-30-PM.png)

Fig.40. Pop-up Gluing

111. Glue flap – glue flap length

112. Glue line from the edge – glue line position from the front edge of the bard

113. Gluing heads – select one or two heads to operate during the cycle

114. Offset for glue – offset between longitudinal scorings and glue line

115. Cutting off – this button opens a pop-up to a set cutting-off side

116. From the left and right side – cutting off the scrap from both sides

117. From the right side – cutting off the scrap from the right side of the input board

118. V – speed parameters – this button open the pop-up Speed described in **7.2.79**

119. Scanning – this button opens a pop-up and starts the procedure of downloading data from an external scanner

120. Machine setup – this indicates that not all information has been entered or machine is not setup.

121. Machine adjusting – setting up the machine to set parameters

122. Machine ready to work – machine is setup to set parameters

123. Start – starts the automatic box production in the current style

124. Stop – stops the machine AFTER the whole board has passed through

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Feb-08-2022-05-29-11-23-PM.png?width=500&name=image-png-Feb-08-2022-05-29-11-23-PM.png)**

Fig. 41. FEFCO 201 STANDARD style setup screen - advanced settings 

125. Blue field - current value of the box panel dimension without allowances

126. White field - allowance value

127. Grey field - total value of panel dimension

**SAVE** **ALLOWANCES** button - pressing the button saves the allowances into the allowances database. The changes made to the allowances will be restored to their previous values after exiting the style. In order to save the allowances permanently, press the **SAVE** **ALLOWANCES** button for about 1 second, the saved allowances will be confirmed by the message “Allowances added.”

****![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Feb-02-2022-05-30-40-10-PM.png?width=50&name=image-png-Feb-02-2022-05-30-40-10-PM.png)*The button is active after logging into the operator's account***

 

**ALARMS, ERROR MESSAGES and FAILURES.** 

If the machine does not operate when required, it is likely that something has been overlooked. In this case, error messages will be displayed on the HMI panel.

**EMERGENCY** **STOP** – the machine was stopped by activation of the **EMERGENCY** **STOP** button or one of the limit switches at the protective covers, to eliminate the reason for this alarm, check if all the machine covers and casings are properly closed or turn the mushroom emergency stop switch clockwise (it will get unlocked). Then press the green **RESET **button.

**LOW** **AIR** **PRESSURE** - no or too low air pressure in the pneumatic system. It should be made sure that the machine is connected to the compressed air system at a suitable pressure level, and then an appropriate pressure in the machine should be set by turning the reduction valve of the compressed air preparation system.

**TOO** **LOW AIR PRESSURE FOR** **CREASING ROLLS**- too low or too high air pressure for longitudinal creases. The alarm is deleted with the **RESET **button.

**ERROR** **SERVO** **DRIVE** **-** **BOARD** – signals the occurrence of an alarm on the servo drive of the travel motor. The alarm is deleted with the **RESET **button**.**

**ERROR** **SERVO** **DRIVE** **-** **LEFT** **CREASING** **BEAM** **-** signals the occurrence of an alarm on the left servo drive of the creasing beam motor. The alarm is deleted with the **RESET **button.

**ERROR** **SERVO** **DRIVE -** **RIGHT** **CREASING** **BEAM** **-** signals the occurrence of an alarm on the right servo motor of the creasing beam. The alarm is deleted with the **RESET** button.

**ERROR** **SERVO** **DRIVE** **-** **CREASING** **ROLLS** **AND** **KNIVES** – signals the occurrence of an alarm on the servo drive of knives and creases. The alarm is deleted with the **RESET **button.

**ERROR** **SERVO** **DRIVE** **-** **ACROSS** **KNIFE** - signals a problem with the servo drive of the transverse knife motor. The alarm is deleted with the **RESET** button.

**CREASING** **ROLLS** **SPACING** **FAULT** – signals a problem with the precise positioning of the creasing rollers at the positions set. The alarm is deleted with the **RESET** button on the HMI touch panel.

**KNIVES** **SPACING** **FAULT** - signals a problem with the precise positioning of the longitudinal knives at the positions set. The alarm is deleted with the **RESET **button on the HMI touch panel.

**ERROR** **DURING** **REFERENCING** **OR** **SPACING** **THE** **ALONG** **TOOL ****GRIPPER** **–** signals a problem with homing or positioning of the longitudinal tool carriage. The alarm is deleted with the **RESET **button.

**ERROR** **DURING** **REFERENCING** **OR** **POSITIONING** **THE** **ACROSS** **–** indicates a problem with homing or positioning of the transverse tool. The alarm is deleted with the **RESET** button.

**ERROR** **DURING** **REFERENCING** **OR** **POSITIONING** **THE** **CREASING** **BEAM ****-** signals a problem with homing or positioning of the creasing beam. The alarm is deleted with the **RESET** button.

**LEFT GUIDE SETUP** **FAULT** – signals a problem with the precise positioning of the limiter in the set position. The alarm is deleted with the **RESET** button.

**SLOTTING** **KNIVES** **SETUP** **FAULT** - signals a problem with the precise positioning of the slotting knives in the set position. The alarm is deleted with the **RESET** button.

**SLOTTING** **KNIVES** **ERROR** **-** **END** **POSITION** **REACHED** **–** signals that the machine has reached the minimum position for the slotting knives during its setting. The alarm is deleted with the **RESET **button.

**SLOTTING** **KNIVES** **ERROR** **-** **CREASING** **BEAM** **NOT** **REFERENCED** **–** setting of the slotting knives is possible after the creasing beam has been homed. The alarm is deleted with the **RESET **button

**MACHINE** **SETTING** **FAULT** **–** signals a wrong setting of the machine for the production cycle. The alarm is deleted with the **RESET **button

**NOT** **ENOUGH** **OF** **CREASING** **ROLLS** **–** signals that the number of longitudinal creasing type is insufficient for a given box.

**NOT** **ENOUGH** **OF** **ALONG** **CUTTING** **KNIVES** - signals that the number of longitudinal knives is insufficient for making a given box.

**NOT** **POSSIBLE** **TO** **SET** **UP** **CREASING** **ROLL** **[1…8]** – the dimensions of the box introduced prevent the spacing of creases in a given position due to the required minimum distance between the tools. If this message occurs, change the orientation of the tools or increase dimensions of the box. The minimum distance between the tools is included in the attachment. The alarm is deleted with the **RESET** button.

**SET** **POSITION** **OUTSIDE** **WORKING** **AREA** **-** **CREASING** **ROLL** **[1…8]** – signals the setting of the longitudinal crease in an inaccessible zone. The alarm is deleted with the RESET button

**NOT** **POSSIBLE** **TO** **SET** **UP** **ALONG** **KNIFE** **[1…8]** – dimensions of the box entered prevent the spacing of knives in a given position due to the required minimum distance between the tools. If this message occurs, change the orientation of the tools or increase dimensions of the box. The minimum distance between the tools is shown in the attachment. The alarm is deleted with then **RESET** button.

**SET** **POSITION** **OUTSIDE** **WORKING** **AREA** **-** **ALONG** **KNIFE** **[1…8]** – signals the setting of the longitudinal knife in an inaccessible zone. The alarm is deleted with the **RESET **button.

**CAN'T** **SETUP** **CREASING** **ROLLS** – signals an attempt to set the longitudinal crease in an inaccessible area. The alarm is deleted with the **RESET **button.

**CAN'T** **SETUP** **ALONG** **CUTTING** **KNIVES** – signals an attempt to set the longitudinal knife in an inaccessible area. The alarm is deleted with the **RESET **button.

**WRONG** **DATA** **FOR** **THE** **ACTIONS** **OF** **CREASING** **ROLLS** **–** signals when the longitudinal action is too short for the longitudinal crease. The alarm is deleted with the **RESET **button.

**WRONG** **DATA** **FOR** **THE** **ACTIONS** **OF** **ALONG** **KNIVES** **–** signals a too short longitudinal action for the longitudinal knife. The alarm is deleted with the **RESET** button.

**WRONG** **DATA** **FOR** **THE** **ACTIONS** **OF** **ACROSS** **TOOL** **-** signals a too short transverse action for the transverse tool. The alarm is deleted with the **RESET **button.

**NO** **SIGNAL** **THAT** **ACROSS** **KNIFE** **IS** **IN** **DOWN** **POSITION** or **NO** **SIGNAL ****THAT** **ACROSS** **KNIFE** **IS** **IN** **UP** **POSITION** **–** signals an incorrect position of the transverse knife. In order to eliminate the cause, check air supply to the actuator, operation of the inductive sensor located on the actuator and mechanical operation of the actuator without air supply to the actuator. The alarm is deleted with the **RESET **button.

**CREASING** **ROLLS** **AND** **KNIVES** **SEARCH** **FAULT** – an alarm occurs during the search procedure for creases and knives. Check the drive system responsible for the spacing of creases and knives. The alarm is deleted with the **RESET **button.

**WRONG NUMBER OF BOARDS TO MAKE –** signals an input format that is too short in relation to the calculated format.

**INPUT** **BOARD** **TOO** **SHORT** – signals an input format that is too short in relation to the calculated format. The alarm is deleted with the **RESET **button.

**INPUT** **BOARD** **TOO** **NARROW** - signals an input format that is too narrow in relation to the calculated format. The alarm is deleted with the **RESET **button.

**INPUT** **BOARD TOO** **LONG** **–** signals that the length of the input format is more than 9000 mm. The alarm is deleted with of the **RESET** button.

**INPUT** **BOARD** **TOO** **WIDE** **–** signals that the width of the input format is more than 2400 mm. The alarm is deleted with the **RESET** button.

**THERE** **IS** **PROBLEM** **WITH** **CARDBOARD** **MOVEMENT** – signals the occurrence of an alarm when the format slips in the machine. The alarm is deleted with the **RESET** button.

**BOARD** **INSIDE** **OF** **THE** **MACHINE** – the message appears after pressing the **START** button or the **HOME** button (the guillotine homing button in the SETTINGS window) when there is a cardboard box or other object under the input or output laser sensor activating it. The alarm is deleted with the **RESET **button.

**EMERGENCY** **STOP** **IS** **PRESSED** **-** **CONTROL** **PANEL** **HMI** or **EMERGENCY STOP** **IS** **PRESSED** **-** **REAR** or **EMERGENCY** **STOP** **IS** **PRESSED** **-** **RIGHT ****SIDE** **–** the messages indicate that one of the safety switches on the machine has been pressed. The alarm is deleted with the **RESET** button**.**

**SAFETY** **GUARD** **IS** **OPENED** **-** **LEFT** **FRONT** or **RIGHT** **FRONT** or **LEFT** **REAR **or **RIGHT** **REAR** or **LEFT** **REAR** **AT** **THE** **BOTTOM** OR **LEFT** **REAR** **AT** **THE ****BOTTOM** – a message indicates the opening of covers on the machine. To reset the alarm, close the covers and press the **RESET** button.

**WINDOW** **IS** **OPENED** **-** **LEFT** or **WINDOW** **IS** **OPENED** **-** **RIGHT** –the opening of a window located on the side wall of the machine. To reset the alarm, close the open window and press the **RESET **button

**REAR** **LEFT** **SAFETY** **GUARD NOT** **BLOCKED** or **REAR** **RIGHT** **SAFETY ****GUARD NOT** **BLOCKED** **–** signals that the lock is not closed. To reset the alarm, press the **RESET **button.

**8.0 Maintenance**

**General Notes**

The machine operators can easily conduct most basic maintenance duties and preventative inspections as the machine is designed and built to operate with minimum maintenance to reduce stoppage periods.

**However, some of the above mentioned operations are strongly recommended to be performed by the Manufacturer's qualified and experienced service technicians (it applies mainly to machine failures).**

Complex maintenance and repair activities should not be performed without obtaining prior permission from the owner or manufacturer.

It is recommended to provide a Machine Repair Log where dates and types of repairs as well as preventative maintenance activities will be recorded.

Under no circumstances should anyone reach into the machine without taking all precautions to eliminate risk by shutting of all electrical and air supplies.

Particularly during maintenance operations or any other manual operations that may be required during preventive inspections, do not place any body parts in real and foreseeable danger zones before eliminating potential and foreseeable emergency situations.

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Feb-04-2022-04-24-20-90-PM.png?width=80&name=image-png-Feb-04-2022-04-24-20-90-PM.png)ATTENTION:** **Work** **performed** **in** **the** **zones** **of** **feeding, cutting** **or** **scoring** **systems** **should** **be** **conducted** **only** **by** **qualified** **personnel** **and** **only** **after** **taking** **all ****precautionary** **measures****.** **In** **the** **above** **mentioned** **zones the highest** **level** **of potential** **body injuries** **is** **possible.**

All machine's operators performing maintenance or preventive activities must always wear protective clothing and ant-slip boots to limit the risk of slipping/falling.

Before performing any work at the machine, always check that cuffs are properly buttoned, zipped around the wrists or neatly tucked up. Personnel should always remember to protect their hair against being pulled into the machine by rollers and belts.

All maintenance or repair activities should be conducted only by qualified personnel who are trained to interpret machine failures, can read diagrams of installed systems and engineering drawings in such a way that all possible disassembly or assembly procedures connected with standard maintenance operations are performed professionally and, most of all, safely.

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Feb-04-2022-04-25-54-80-PM.png?width=40&name=image-png-Feb-04-2022-04-25-54-80-PM.png) ATTENTION:** **Switchbox** **inspection** **and** **electrical** **systems** **maintenance** **can** **be** **performed** **only** **by** **certified** **electricians** **with valid** **training.**

**![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Feb-04-2022-04-25-54-80-PM.png?width=40&name=image-png-Feb-04-2022-04-25-54-80-PM.png) ATTENTION:** **Under** **no** **circumstances** **should** **any** **of** **the maintenance,** **repair or** **preventative** **activities** **be** **conducted** **when** **the machine** **is** **operating or is** **connected to a** **power** **supply** **unit.**

**Preventative Program, Periodical Inspection**

***AT**** ****THE BEGINNING**** ****OF EACH WORKING SHIFT**** ****CHECK**** ****IF:*****

- working space is clean, clear and safe;
- check the amount of solid impurities, leaks, and dust settling in/on the machine and all its components, if necessary clean it with a vacuum cleaner or a compressed air gun;
- clean the bottom knives in the counter-top;
- visually check the closing of all protective covers;
- sufficient level of lightning is provided to the working space;
- check the effectiveness of safety switches (**EMERGENCY** **STOP**), limit switches protecting movable covers and safety locks;
- ***Check**** ****AFTER**** ****100**** ****WORKING HOURS**** ****of the machine –**** ****or weekly:***
- correct attachment and tightening of the load-bearing screws; check the tension of transport drive belt;
- clean the filter in the air preparation assembly
- ***Check**** ****AFTER**** ****1,000**** ****WORKING**** ****HOURS**** ****of**** ****the**** ****machine**** ****–**** ****or**** ****every**** ****3  ******months:***
- check effectiveness of the electric shock protection
- visually check the condition of mechanical components
- tighten all screw connections
- check the condition of the basic contact elements (contactors, relays), replace elements with worn connection surfaces.

**9.0 Occupational and Safety Rules**

The built-in safety features within the machine are designed to minimize any failures and to ensure that the safety requirements are met to minimize the risk of injury by maintaining a high level of safety.

***The**** ****machine**** ****has**** ****many**** ****integrated**** ****safety**** ****features**** ****for**** ****the**** ****protection**** ****of operators and other personnel**** ****including******:*****

- *time-delay** **fire** **protection*;
- *limit** **switches to** **detect** **open/insecure** **covers** **and** **guards*;
- safety lock with a latch
- *decay** **phase** **sensor*;
- *covers and** **guards** **to** **protect from movable** **parts of the** **machine*;
- *easily** **accessible** ****EMERGENCY**** ****STOP**** **button** **installed** **on** **the** **main** **control panel;*
- *additional** **protection** **systems** **implemented** **in** **machine's** **control algorithm in** **order to** **halt** **the** **machine** **in** **potentially** **dangerous situations;*
- *the** **machine** **construction** **designed** **to** **provide** **the** **maximum** **level** **of** **safety for its** **operators.*

**Basic Safety Rules**

Issues connected with safety rules and the evaluation of potential risk deriving from human-machine contact have been thoroughly covered in previous chapters of this service manual in which similar situations were presented. However, the importance of personnel safety is so profound that the Manufacturer has repeated the information once more here.

- *All** ****BOXMAT**** ****PRO**** **operators** **must** **be** **acquainted** **with** **general** **safety** **rules implemented** **in** **the** **industrial workplace.*
- *In** **order** **to** **perform** **the** **optimal** **and** **safe** **machine** **use,** **this** **service manual** **should** **be** **read** **thoroughly** **and** **the** **user** **is** **strictly** **advised** **to** **follow** **all** **the** **instructions ****with a**** ****special focus**** ****on**** ****safety**** ****and**** ****warning**** ****signs.***
- *The** **final** **legal** **and** **financial** **responsibilities** **for** **all** **and** **any** **potential** **events derived** **from** **either** **the** **ignorance** **of** **the** **text** **of** **this** **service** **manual** **or** **the safety** **and** **occupational** **rules** **lies** **upon** **the** **purchaser.** **It** **is** ****COMPLETELY**** ****AND**** ****ABSOLUTELY**** ****OBLIGATORY**** **to** **read** **and** **follow** **these** **instructions.*
- *On** **the** **basis** **of** **the** **text** **included** **in** **this** **service** **manual** **and** **the** **knowledge derived** **from** **the** **manufacturer’s** **own** **product** **technology** **experience,** **the purchaser** **is** **strictly** **obliged** **to** **work** **out** **their** **own** ****WORK**** ****STATION INSTRUCTIONS**** **for their** **own** **machine operators.*
- *Each** **operator** **should** **read** **the** **text** **of** **this** **service** **manual** **before performing** **any** **work** **at** **the** **machine** **and** **should** **read** **any** ****WORK**** ****STATION INSTRUCTION.***
- ***Under**** ****no**** ****circumstances**** **should** **the** **machine** **be** **operated** **by** **untrained** **personnel.** **The** **machine** **operators** **must** **be** **familiar** **with** **the** **occupational health** **and** **safety** **rules,** **and** **with** **a** **special** **focus** **on** **the** **risk** **created** **by** **the machine.*
- *Periodical** **preventative** **inspection** **of** **the** **fire** **protection** **system** ****must**** ****be**** ****performed**** **in** **the** **operated** **machine.** ****The**** ****purchaser**** ****is**** ****fully**** ****responsible**** ****for making arrangements**** ****for conducting**** ****such**** ****inspection***
- *According** **to** **the** **manufacturer’s** **recommendations,** **the** **machine** **should** **be** **installed** **in** **the industrial environment** ****only.***
- *Life** **threatening** **level** **of** **high** **power** **network** **voltage** **of** **3** **x** **480** **VAC,** **50/60 Hz** **is** **delivered** **to** **the** **machine.** **As** **a** **result,** **all** **service** **or** **preventative activities** **should** **be** **performed** **only** **by** **well-trained** **personnel** **with** **qualifications** **required** **by** **law.*
- ***UNDER**** ****NO**** ****CIRCUMSTANCES**** **should** **any** **measures** **leading** **to decrease** **the** **machine** **safety** **status** **(such** **as** **blocking** **master** **switches** **or** **removing** **shields** **etc.)** **be** **undertaken** **by** **the** **purchaser** **or** **operator*
- *Any** **maintenance** **or** **other** **activities** **performed** **when** **the** **machine** **is** **running** **or** **when** **at** **a** **lowered** **standard** **of** **machine** **protection** **(while** **the shields** **are** **open** **or** **when** **the** **safety** **switches** **are** **defeated)** **must** **be** **kept to** **an** **absolute** **minimum before** **the full** **status** **of safety is restored*.
- ***UNDER**** ****NO**** ****CIRCUMSTANCES**** **should** **the** **machine** **be** **assembled,** **disassembled** **or** **transported** **by** **unqualified** **personnel** **or** **those** **unfamiliar** **with** **the** **safety** **rules** **included** **in** **this** **service** **manual** **as** **the** **said** **activities** **may lead to** **an accident** **or may** **become** **the** **cause of** **financial** **losses.*
- *The** **machine’s** **initial** **start-up** **should** **be** **conducted** **in** **the** **presence** **and under** **the** **supervision of** **Contractor’s** **agents.*
- *The** **machine’s** **test** **procedure,** **implemented** **always** **before** **the** **Buyer** **is** **entering** **the** **phase** **of** **full** **use** **of** **the** **machine,** **shall** **be** **performed** **only** **by an** **authorized** **person.*
- *Any** **change** **of** **any** **part,** **or** **use,** **of** **the** **machine** **which** **is** **inconsistent** **with** **that** **described** **in** **this** **service** **manual** **may** **lead** **to** **machine** **failures** **or** **become** **the** **cause** **of an** **accident.*
- ***The**** ****machine's**** ****work parameters**** ****were**** ****pre-set**** ****by**** ****the**** ****Manufacturer**** ****in the**** ****most**** ****optimal**** ****way**** ****due**** ****to**** ****the**** ****installed**** ****rollers,**** ****cutting**** ****or**** ****scoring tools**** ****and**** ****electronic**** ****control**** ****systems.**** ****Any**** ****change**** ****in**** ****the**** ****machine's**** ****working**** ****parameters**** ****without**** ****the**** ****Manufacture's**** ****knowledge**** ****and**** ****permission may lead**** ****to an**** ****accident**** ****or poor**** ****performance.***

**Safety Conditions for the Personnel Directly Operating the Machine**

***![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Feb-04-2022-04-25-54-80-PM.png?width=40&name=image-png-Feb-04-2022-04-25-54-80-PM.png) ATTENTION:**** ****To**** ****prevent**** ****serious**** ****injury,**** ****it**** ****is**** ****essential**** ****that**** ****all**** ****covers**** ****and**** ****guards**** ****are**** ****kept**** ****in**** ****place**** ****to**** ****protect**** ****personnel**** ****from**** ****the**** ****dangers**** ****present**** ****from**** ****moving**** ****shafts,**** ****blades,**** ****knives,**** ****etc.**** ****while operating this box-making machine.***

- *It** **is** **advised** **that** **all** **and** **any** **personnel** **working** **with** **this** **or** **any** **other machinery** **should** **be** **trained** **and** **equipped** **to** **offer** **first** **aid** **assistance** **to any persons in** **the event** **of** **falls or** **accidents**.*
- *The** **area** **surrounding** **this** **or** **any** **machine** ****should**** ****not**** **be** **blocked** **by** **any obstacles** **or** **waste** **product** **during** **its** **regular** **work** **cycle** **as** **this** **may** **cause stumbles,** **slips,** **falls** **or** **other accidents.*
- *The** ****EMERGENCY**** ****STOP**** **button** **is** **designed** **to** **be** **pressed** **at** **any** **time especially** **when an emergency** **shut-down** **is** **promptly needed.*
- ***UNDER**** ****NO**** ****CIRCUMSTANCES**** **should** **any** **moving** **parts** **of** **the** **machine be** **touched** **when** **working.*
- ***UNDER**** ****NO**** ****CIRCUMSTANCES**** **should** **any** **water** **based** **fire** **extinguisher** **equipment** **be** **used** **on** **or** **near** **the** **machine.** **Use** **only** **licensed** **non-water based** **firefighting agents** **and** **fire hazard** **protection** **products.*
- ***UNDER**** ****NO**** ****CIRCUMSTANCES**** **should** **any** **guards** **or** **covers** **be** **removed during** **machine** **work** **cycle.*
- ***UNDER**** ****NO**** ****CIRCUMSTANCES**** **should** **the** **operators** **stand** **or** **climb** **on** **the** **guards** **or covers.*
- ***UNDER**** ****NO**** ****CIRCUMSTANCES**** **should** **the** **operators** **stand** **or** **climb** **on** **the** **guards** **or covers.*
- ***UNDER**** ****NO**** ****CIRCUMSTANCES**** **should** **any** **oil,** **solvent** **or** **other** **caustic** **or** **toxic substances** **be** **allowed** **to** **come into** **contact** **with** **the** **machine.*
- ***UNDER**** ****NO**** ****CIRCUMSTANCES**** **should** **mobile** **phones** **be** **used** **near** **the machine** **direct** **environment.*
- ***UNDER**** ****NO**** ****CIRCUMSTANCES**** **should** **naked** **flames** **be** **used** **in** **the machine** **direct** **environment.*
- ***UNDER**** ****NO**** ****CIRCUMSTANCES**** **should** **cigarettes** **be** **smoked** **in** **the machine** **direct** **environment.*
- ***UNDER**** ****NO**** ****CIRCUMSTANCES**** **should** **alcohol** **be** **consumed** **in** **the machine** **direct** **environment** **nor** **should** **personnel** **under** **the** **influence** **of** **alcohol** **operate** **the machine.*
- ***UNDER**** ****NO**** ****CIRCUMSTANCES**** **should** **personnel** **consume** **meals** **in** **the** **machine** **direct** **environment.*
- ***IT**** ****IS**** ****ESSENTIAL**** **to** **use** ****ALL**** **covers** **and** **guards** **designed** **for** **the machine.*
- ***IT**** ****IS**** ****ESSENTIAL**** **that** **any** **accidents** **or** **machine** **failures** **should** **be** **promptly reported** **to the** **management.*
- ***IT**** ****IS**** ****ESSENTIAL**** **to** **use** **suitable** **working** **clothing** **to** **limit** **the** **possibility** **of** **being** **snagged or** **dragged** **into** **the machine.*
- ***IT IS**** ****ESSENTIAL**** **to** **wear protective** **gloves while** **operating** **the machine.*
- ***IT IS**** ****ESSENTIAL**** **to** **wear anti-slip, safety footwear*.
- ***IT IS**** ****ESSENTIAL**** **to use** **hair** **covering to minimise** **the** **possibility** **of** **being** **snagged** **or** **pulled** **into** **the** **machine.*
- ***IT**** ****IS**** ****ESSENTIAL**** **to** **keep** **the** **floor** **around** **the** **machine** **clean** **and** **clear** **of all** **debris and** **waste** **material.*
- ***IT IS**** ****ESSENTIAL**** **to** **use** **hearing** **protection.*
- ***IT**** ****IS**** ****RECOMMENDED**** **to** **use** **the** ***EMERGENCY** **STO*P**** **button** **whenever there** **is** **a** **situation** **where the** **machine** **or** **the** **operator** **are** **at** **risk.*
- *Careless** **handling** **of** **the** **machine** **during** **transport** **and/or** **relocation** **may lead** **to** **severe** **injuries** **or** **accidents*.
- *Only** **suitably** **trained** **personnel** **taking** **special** **precautionary** **measures** **can perform** **certain** **tasks** **inside** **the** **machine.** **In** **these** **areas** **there** **is** **increased** **risk of** **severe** **injuries.*
- *At** **no** **time** **should** **operators** **climb on** **the machine.*
- *The** **switchbox** **doors** **should** **always** **be** **closed** **even** **if** **the** **machine** **is** **not** **in** **operation.*
- *The** **machine** **operators are strongly** **advised** **to work only** **in** **the** ***safe work ***zone which is outlined in the drawing below:*

*![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Feb-04-2022-05-42-08-84-PM.png?width=500&name=image-png-Feb-04-2022-05-42-08-84-PM.png)*

Fig. 42. Tolerable boundaries of work zone during work cycle performed by Boxmat PRO. The area in which the machine's operators are not allowed to stay and perform their tasks at the machine was marked with the use of red color -the clearance zone around the machine should be no less than 59”.

**Workplace Safety Rules During Maintenance, Repair, and Preventative Activities**

- ***UNDER**** ****NO**** ****CIRCUMSTANCES**** **should** **any** **service,** **maintenance** **or** **preventative** **measures** **be** **undertaken** **without** **full** **disconnection** **from supply** **network*
- ***UNDER**** ****NO**** ****CIRCUMSTANCES**** **should** **the** **machine** **be** **lubricated,** **cleaned** **or** **maintained while** **it** **is** **in** **operation.*
- *Switchbox** **and** **electrical** **systems** **maintenance** **can** **be** **performed** ****only**** **by suitably** **trained** **and** **qualified** **electrical engineers.*
- *Under** **no** **circumstances** **should** **the** **machine** **maintenance** **be** **conducted** **by** **unqualified** **or** **inexperienced** **engineers** **who** **are** **unfamiliar** **with** **the machine** **electrical wiring*.
- *Personnel** **performing** **maintenance** **activities** **should** **wear** **suitable** **protective** **clothing*.
- *Under** **no** **circumstances** **should** **the** **electrical** **system** **be** **modified** **in** **any way.*
- *The** **doors** **of** **the** **control** **system** **cabinet** **should** **be** **always** **locked** **and** **only authorized personnel** **should** **have** **access** **to the** **key*.

**Summary**

*Suitable** **measures** **should** **be** **taken** **during** **machine** **operation,** **its** **transport** **and installation** **procedures,** **and** **the** **repair,** **maintenance** **and** **preventative** **routines, to** **prevent** **the** **following** **situations*:

- *The** **machine** **should** **not** **be** **used in** **any** **way** **other** **than** **described** **herein*;
- *The** **machine** **should** **not** **be** **connected** **electrically** **with** **disregard** **to** **the provisions** **included** **herein*;
- *The** **machine** **should** **not** **be** **used** **inappropriately** **or** **used** **by** **untrained** **personnel;*
- *The** **machine** **should** **not** **be** **used** **with** **unsuitable** **materials*;
- *There must** **be** **sufficient** **suitable** **maintenance*;
- *There** **must** **be** **no** **unauthorized** **changes** **or** **alterations** **by** **unqualified** **or untrained personnel*;
- *There must** **be no use of** **non-original** **spare** **parts*;
- *There** **must** **be** **no** **personnel** **activities** **breaching** **the** **law** **and/or** **the regulations** **applicable** **to** **the** **workplace,** **as** **well** **as** **the** **provisions** **included** **in** **this** **service manual*.

**10.0 Electrical Documentation**

**10.1 POWER** **SUPPLY** **PARAMETERS** **–** **TECHNICAL** **DATA**

Supply voltage                                                          3 x 230 VAC; 50/60 Hz

Control voltage                                                         24 VDC

Maximum power consumption                             5.5 kW

**10.2 LIST OF ELECTRICAL** **APPARATUS**

*See** **enclosure.***

**10.3 WIRING** **DIAGRAM**

*See** **enclosure*.

**11.0 Pneumatic Documentation**

**11.1.** **TECHNICAL DATA**

Working pressure 0.6 – 0.8 MPa

Filtration accuracy 20 μм

Required class of working medium activity

4-4-4 according to ISO8573-1 standards

**11.2 PRINCIPLE OF OPERATION**

The working medium which is introduced to the system with the help of pressure reducing valve is subject to the initial filtration and then the reduction procedure due to which it is reduced to the required level. Then with the help of distribution valve controlled by the electro-pneumatic system the medium is delivered to the adequate servo-motor and as a result the said servo-motor is put in motion. Finally, the servo-motor motion will cause the relocation of razor blade due to which the glue flap will be cut off.

***![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Feb-04-2022-04-25-54-80-PM.png?width=40&name=image-png-Feb-04-2022-04-25-54-80-PM.png) ATTENTION:**** ****The**** ****purchaser**** ****is**** ****strongly**** ****advised**** ****to**** ****maintain**** ****the adequate**** ****4-4-4**** ****class**** ****of**** ****air**** ****cleanliness**** ****according**** ****to**** ****ISO8573-1 requirements**** ****even**** ****though**** ****the**** ****Manufacturer**** ****equipped**** ****the**** ****machine in the**** ****compressed-air**** ****preparation**** ****system.*****

**11.3 INSTRUCTIONS FOR ****USE**

The above mentioned pneumatic system does not require an extreme amount of attention, though, the user is obliged to control the level of condensation water in compressed-air filter tank periodically. If the presence of water is found, it should be emptied. If the significant amount of solid impurities in the tank are found, the tank must be dismantled, and then cleaned out with suitable cleaners. After cleaning out it should be aired with compressed-air and refitted. The detailed description of compressed-air system can be found in part titled CONTROLS AND INDICATORS AVAILABLE for OPERATOR.

**11.4.** **PNEUMATIC SYSTEM DIAGRAM**

*See** **enclosure*.

**12.0 Utilization and Machine-Breaking**

**12.1 GENERAL NOTES**

Introduced changes in law provisions or in process standards, which could not have been foreseen earlier, may become the cause of utilization and machine- breaking. This issue applies also to the machine's replaced or repaired parts and systems. In consequence, the purchaser is solely responsible for conducting the above mentioned procedures according to the binding provisions of law. It should be noted, however, that all machine's parts can be fully recycled.

**12.2 WASTE MATERIAL**

Hazardous waste should be always utilized by the companies which specialize in dealing with this kind of issue on a regular basis. The detailed list of type of waste produced by the machine in its life span is attached below:

- cardboard, corrugated board and other waste products;
- worn-out spare parts, which are divided into types of material from which they are made.
- All waste material deriving from machine parts' replacement or servicing even partially contaminated by grease cannot be discarded along with the industrial waste products.

***![](https://www.weldmaster.com/hs-fs/hubfs/image-png-Feb-04-2022-04-25-54-80-PM.png?width=40&name=image-png-Feb-04-2022-04-25-54-80-PM.png) ATTENTION:**** ****It**** ****is**** ****strictly**** ****forbidden**** ****to**** ****place**** ****hazardous**** ****waste directly**** ****into**** ****the**** ****waste**** ****containers**** ****or**** ****use**** ****the**** ****municipal**** ****waste collectors**** ****to dispose**** ****of it.***

**12.3** **PHASES ****OF** **DISMANTLING ****PROCEDURE** **IMPLEMENTED for MACHINE-BREAKING**

- Use MASTER SWITCH to switch off the machine;
- Machine must be placed in stable position on the floor.;
- Disconnect the machine from both pneumatic and electric power sources;
- Detach from the machine and disassemble both work tables (if they were ordered);
- Disconnect the flexible connections made of plastic and rubber, then utilize them with the help of companies which specialize in dealing with this kind of waste;
- Disconnect wiring systems and electrical equipment and then utilize them with the help of companies which specialize in dealing with this kind of waste.
- Divide metal waste into steel and non-ferrous and then break them up for scrap with the help of companies which specialize in dealing with this kind of waste.

**13.0 Enclosures**

**Rating Plate**

![](https://www.weldmaster.com/hubfs/image-png-Feb-08-2022-05-50-39-36-PM.png)

**14.0 Additional Machine Documents**

- [Technical Spec Sheet](https://www.weldmaster.com/hubfs/Technical%20Spec%20Sheets/SpecSheet-PS150.pdf)

 

 

[**Back to Top**](https://www.weldmaster.com/manuals/boxmatproi#back-to-top)

## Machine Videos

- Overview & How Tos
- Training Videos

[![Why Consider Automated Box Making Machines?](https://img.youtube.com/vi/VzBmbNFFoP8/0.jpg)

![play icon](https://www.weldmaster.com/hubfs/Images/Icons/play-icon.png) 

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### Why Consider Automated Box Making Machines?

[![Automated Corrugated Box Making Machinery](https://img.youtube.com/vi/YdxEOA2h1kY/0.jpg)

![play icon](https://www.weldmaster.com/hubfs/Images/Icons/play-icon.png) 

](https://www.youtube.com/watch?v=YdxEOA2h1kY&rel=0)

### Automated Corrugated Box Making Machinery

[![Fastest Short Run Corrugated Boxmaking Machine](https://img.youtube.com/vi/8ft6Z-yzwtE/0.jpg)

![play icon](https://www.weldmaster.com/hubfs/Images/Icons/play-icon.png) 

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### Fastest Short Run Corrugated Boxmaking Machine

[![Small Printer for Corrugated Boxes](https://img.youtube.com/vi/ao-0cpSW-wY/0.jpg)

![play icon](https://www.weldmaster.com/hubfs/Images/Icons/play-icon.png) 

](https://www.youtube.com/watch?v=ao-0cpSW-wY&rel=0)

### Small Printer for Corrugated Boxes

[![Corrugated Cardboard Stacker For Boxmaker](https://img.youtube.com/vi/I1n1W8rU3NU/0.jpg)

![play icon](https://www.weldmaster.com/hubfs/Images/Icons/play-icon.png) 

](https://www.youtube.com/watch?v=I1n1W8rU3NU&rel=0)

### Corrugated Cardboard Stacker For Boxmaker

[![Automatic All In One Box Making Machine](https://img.youtube.com/vi/VdF5ElFV-Co/0.jpg)

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](https://www.youtube.com/watch?v=VdF5ElFV-Co&rel=0)

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[![Boxmaker with Perforating Knives to make Special Boxes](https://img.youtube.com/vi/3086vEfTf3g/0.jpg)

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](https://www.youtube.com/watch?v=3086vEfTf3g&rel=0)

### Boxmaker with Perforating Knives to make Special Boxes

[![Boxmaking with Automatic Glue Applicator](https://img.youtube.com/vi/Z2a92slrsyA/0.jpg)

![play icon](https://www.weldmaster.com/hubfs/Images/Icons/play-icon.png) 

](https://www.youtube.com/watch?v=Z2a92slrsyA&rel=0)

### Boxmaking with Automatic Glue Applicator

[![Machine for Making Cardboard Packaging](https://img.youtube.com/vi/EFuH46xBBOg/0.jpg)

![play icon](https://www.weldmaster.com/hubfs/Images/Icons/play-icon.png) 

](https://www.youtube.com/watch?v=EFuH46xBBOg&rel=0)

### Machine for Making Cardboard Packaging

[![Full Production Line with Automatic Feeder](https://img.youtube.com/vi/WBnkZQFE8Q0/0.jpg)

![play icon](https://www.weldmaster.com/hubfs/Images/Icons/play-icon.png) 

](https://www.youtube.com/watch?v=WBnkZQFE8Q0&rel=0)

### Full Production Line with Automatic Feeder

[![Boxmaker with Full Size Printing](https://img.youtube.com/vi/OtO0Q_AP15g/0.jpg)

![play icon](https://www.weldmaster.com/hubfs/Images/Icons/play-icon.png) 

](https://www.youtube.com/watch?v=OtO0Q_AP15g&rel=0)

### Boxmaker with Full Size Printing

[![Gluing System for Cardboard Boxes Production](https://img.youtube.com/vi/YIM1fmkGjrU/0.jpg)

![play icon](https://www.weldmaster.com/hubfs/Images/Icons/play-icon.png) 

](https://www.youtube.com/watch?v=YIM1fmkGjrU&rel=0)

### Gluing System for Cardboard Boxes Production

[![Making Boxes from Fanfold / Z-fold Cardboard](https://img.youtube.com/vi/zT3msdxHrQw/0.jpg)

![play icon](https://www.weldmaster.com/hubfs/Images/Icons/play-icon.png) 

](https://www.youtube.com/watch?v=zT3msdxHrQw&rel=0)

### Making Boxes from Fanfold / Z-fold Cardboard

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