DROP PACKER SYSTEM DESCRIPTION AND SET UP

DROP PACKER SYSTEM DESCRIPTION AND SET UP

Description, Installation, and Set Up Procedures: Page 1

INTRODUCTION

In order to achieve maximum production and reliability from this system, it is necessary to be familiar with its capabilities. Knowledge of installation, components, and set up are essential to initiate operations. Presented in this section are the proposals for the preferred site location, information on securing the system, pneumatic, and electrical information. Electrical and Pneumatic schematics are located in section three and the back jacket of this manual. This information will provide steps to continued operations and enhanced production. Proper installation, knowledge of the systems components, and detailed set up are necessary in the operations. Thorough understandings of these basics are essential.



GENERAL DESCRIPTION

This COMBI PACKAGING SYSTEMS MODEL 2DP DROP PACKER, MODEL E2000 CASE ERECTOR AND TBS100FC CASE SEALER SYSTEM is a medium speed automatic case erector, case packer and case sealer system for RSC (Regular Slotted Case) type cases for round and non-round products. Cases can be sealed top and bottom with pressure sensitive tape or with hot melt glue, if desired. The case, when presented to the machine, is belt driven through the sealer with precise and positive application. There are four basic models available to handle a wide variety of case dimensions. This machine is designed for easy change over from one size product to another, from one pack pattern to another and from one case size to another.

CAUTION:

ALL ADJUSTMENTS SHOULD BE MADE WITH THE EMERGENCY STOP BUTTON DEPRESSED. THIS MACHINERY CAN CYCLE AUTOMATICALLY WITHOUT MANUAL MANIPULATION. TO PREVENT INJURY, DURING NORMAL OPERATION, KEEP ALL SAFETY COVERS IN PLACE AND DO NOT DISENGAGE SAFETY SWITCHES.

Due to variations in RSC type cases and product sizes, minor adjustments and variations in set up procedures may be required. Machine speeds are dependent on case size and construction.

Diagrams and photos may vary slightly from actual equipment.



GENERAL INSTALLATION INSTRUCTIONS

1. SITE LOCATION

Ideally, the main electrical enclosure should be located away from direct heating and cooling or windows where it can be affected in direct sunlight. Equipment should be located convenient to the required utilities, such as compressed air and power, as well as being convenient to related production facilities.

There should be ample room around the case magazine to provide access for corrugated delivery and loading. There should be clearance around the equipment to accommodate production and maintenance functions. A minimum of 36” clearance must be left to the front of the electrical enclosure (check your local electrical codes). The flooring must be suitable to secure the proper anchor bolts, as they are required to maintain structural alignment and keep the equipment from moving (or “walking”) out of position. 2. STRUCTURAL ERECTION

When the exact location has been determined, the location for the anchor bolts should be marked on the floor.

The use of tightly drawn wire as a “centerline”, and a plumb bob to transfer the stations and

centerline to the floor, is an excellent way to begin the anchor bolt layout. Proper use of a transit and/or triangulation may be used to determine the exact anchor bolt

locations. The use of a transit could make it possible to note and record the variation in floor elevation at each anchor location.

The structure should be leveled both longitudinally and transversely by means of the

adjustable foot bolts in each leg. Connecting brackets, provided by Combi Packaging Systems, are used to interconnect equipment. Most connections will be labeled.

Exercising proper care in this phase of erection will help to assure that all sections will fit

together properly, will contribute to the reliability of the system, and to minimize unnecessary damage.



GENERAL INSTALLATION INSTRUCTIONS CONT. 3. ELECTRICAL CONNECTIONS

All electrical connections between equipment are made terminal to terminal. A junction box is provided on each piece of equipment, other than that which has the main enclosure. A set or row of terminal strips is located on each sub panel in each terminal box. The terminals are prewired with the internal wiring to that specific component. The terminals are numbered to coincide with the external wiring, which is also numbered. The wiring is disconnected at one end and left generally in flexible conduit ready to reconnect. Check the electrical schematic located in the electrical enclosure for incoming power required.

4. COMPRESSED AIR CONNECTIONS Compressed air is brought in to one or more locations, (see your equipment layout). Air should be delivered via a 3/4” or larger air line, 80-psi minimum supply, to the filter regulator.

An air connection between equipment is generally via polyflow tubing. These must be reconnected directly into the valve or cylinder via a quick connect fitting. Both ends, fitting and tube, will frequently be labeled, (unless connection is obvious).

DROP PAC SYSTEM DESCRIPTION AND SET UP


KER CONTROL PANEL

Figure 1. Operator Control Panel

NOTE: SOME PANEL LAYOUTS AND SWITCH LABELS MAY VARY SLIGHTLY FROM MACHINE TO MACHINE.

The Operator Control Panel is used to control the automation of the system. 1. "EMERGENCY STOP" - Red “mushroom” push button when depressed, will remove power

and release air pressure to the pneumatic system. This button should not be used during normal operation. NOTE: When servicing machines, disconnect power at main power panel disconnect switch. Emergency Stop push button also located on Sealer.

2. "SAFETY RESET" - Blue push button. The machine is reset.



FLOW CONTROL ADJUSTMENT

NOTE: SOME MACHINES MAY DIFFER – PLEASE REFER TO YOUR PNEUMATIC SCHEMATIC FOR “SV” LABELING

Flow control of air-activated components is factory set and should not need adjustment. However, if you are not satisfied with the standard settings, they may be modified at the Valve Bank. The Extend Flow Control adjustment screw (top) adjusts the flow to the bottom output air line, while the Retract Flow Control adjustment screw (lower) controls the upper output air line. There is air flow in the top air line when the valve is energized (normally closed), and air flow is in the bottom air line when the valve is de-energized (normally open). Turning the Flow Control screw clockwise restricts the flow through the valve while turning it counter-clockwise increases the air flow through the valve. To check your adjustments, depress the manual over-ride button that will actuate the valve without running the machine. Example: If you desire to slow the extension of a cylinder that is normally retracted (de-energized), loosen the lower flow control nut, turn the screw clockwise, tighten the nut, and test by pressing the manual over-ride button. Note: If the coil is on the bottom (reversed) the top flow control and lower adjustment may be reversed.

NOTE: DO NOT ADJUST SV/01 – THE AIR FLOW MUST STAY UNRESTRICTED



CASE VACUUM

Figure 2. Figures 2, 3, 4, and 5 illustrate the Case Vacuum. The Case Vacuum grasps the case from the magazine for erection. A description is listed in system set up procedures section.

DROP PACKER SYSTEM DESCRIPTION


CASE VACUUM CONTINUED Note: This option only pertains if the small vacuum cup option was selected at time of purchase.

Vacuum Cups placed for large case. Figure 3.

Figure 4. This option only pertains if the small vacuum cup option was selected at time of purchase. Shut off unused vacuum lines here.

Figure 5. This option only pertains if the small vacuum cup option was selected at time of purchase. Vacuum Cups placed for small case. Note removal of unused cups and extension arm. NOTE: Be sure to shut off unused vacuum lines.


Description, I

CASE MAGAZINE

The Case Min the syste

nstallation, and Set Up Procedures: Page 9

CASE OPENER SPRING

Figure 6. agazine contains the cases for erection. A complete sequence of operation is presented

m set up procedures section.



CASE PLOW

Figure 7. – Case Plow Adjustment Handles and case guide handles.

Figure 9. – Case Plow.

The Case Plow is the mechanism that effects the formation of the case. The main parts of the plow are the Lead Minor Break, the Inside Plow and Outside Plow. Additional information is available in the system set up procedures section.

Figure 8. – Case Width Measurement Handles (Circular).



TAPE HEAD (IF APPLICABLE) Tape head information may vary from machine to machine. Refer to tape head manual for specific instructions.

1. Stop the Case Erector by pushing EMERGENCY STOP button on the Operator Control Panel.

2. Remove cases from the taping area. 3. Place Tape Head Roller Hold Down over Tape Head. 4. Pull on Indexing Plunger. 5. Pull Tape Head carriage out gently. 6. Remove Tape Head Roller Hold Down. 7. Tape Head removal and/or servicing can now be done. 8. After servicing Tape Head, replace Tape Head Roller Hold Down. 9. Push Tape Head Carriage back until indexing plunger clicks into place. 10. Restart machine. 11. Check tape seal and make proper adjustments if needed.

Figure 10.



ALARMS

This only pertains if the alarm options were selected at time of purchase.

Any tape faults will shut down the taper automatically.

BLUE - SOLID Low Case or Low Tape

BLUE – FLASHING No Tape or No Tape Cut

Correct problem as noted by the alarm and push “ERECTOR START”.

DROP PACKER SYSTEM SET UP PROCEDURES

Description, Installation and Set Up Procedures: Page 13

CASE ERECTOR STANDARD SET UP PROCEDURES

NOTE: ALL ADJUSTMENTS ARE TO BE USED AS A GUIDELINE FOR INITIAL

SET-UP. THESE ADJUSTMENTS MAY HAVE TO BE CHANGED AFTER ACTUAL RUNNING CONDITIONS ARE ACHIEVED. EACH PRODUCT IS DIFFERENT, AND MACHINE MUST BE ADJUSTED ACCORDINGLY.

1. Push Emergency Stop before starting set up. See figures 2 and 3. 2. Close the Main Air Shutoff Valve at the FRSS Main Air handling unit on the back of the machine.

(Push the orange tab down. See figure 1.) Note: Airflow to the machine must be stopped to manually set up the machine.

3. Stopping the main air released air pressure to all pneumatic components and allows them to be moved manually. See Final step to reset the FRSS.

Figure 1. Main Air Figure 2. Control Panel Location



CONTROL PANEL

Emergency Stop

Safety Reset

Figure 3.

NOTE: SOME PANEL LAYOUTS AND SWITCH LABELS MAY

VARY SLIGHTLY FROM MACHINE TO MACHINE.

1. "EMERGENCY STOP" - Red “mushroom” pushbutton, when depressed, will remove power and release air pressure to the pneumatic system. This button should not be used during normal operation. NOTE: When servicing machines, disconnect power at main power panel disconnect switch. There is also an Emergency Stop pushbutton located on Sealer.

2. “SAFETY RESET” – “Blue pushbutton” resets the Emergency Stop (E-Stop)



Fold bottom flaps and use measuring ruler to determine dimensions of the case. Record the dimensions.

Minor Side

Figure 4. Figure 5.

Major Side

Bottom Flap Folded

Figure 6.



Crank the Magazine Height Adjustment handle until pointer reads proper height measurement.

Figure 8. Case Magazine indicator Figure 7.

Case magazine

1. Magazine set up procedures. Measure the width and height of the case to be

erected. (Height equal to height with the top flap up (Top flap only, See Figure 6).

2. Move the Magazine Case Guide (The minor side is the side with the shortest flap to the proper width measurement). See figure 9 through 12.

3. Move the Magazine Case Guide (The major side is the side with the longest flap) to allow the case to flow down the magazine freely but also retained by the Hyfax Wedge (See figure 12) at the end of the Magazine. Loosen the opposite Case Side Guide so that there are a 3/8” – 1/2” gap between it and the side of the case.

4. Crank the Magazine Height Adjustment Case Hold Down to the same height measurement. See figures 22 and 23.



Loosen locks and move the Magazine Case Guide (minor side) until pointer reads proper width measurement.

Figure 9. Figure 10.

Minor Side

Adjust the Magazine Case Guide (major side) similarly but leave a 3/8”-1/2” gap between Guide and case.

Major Side

Wedge

Flow




Load cases and swing Case Follower into position.

Minor Flap

Major FlapMajor Side


Loosen lock and adjust the Upper Case Opener Spring so that there is about 3/8”engagement with top of case.




Do the same for the Lower Case Opener Spring.

Figure 17.

Magazine set up procedures continued. 5. Adjust the Case Opener Spring (Figures 15, 16, 17) by loosening the Locking

Handle until there is about 3/8” of engagement from the top of the case and the spring. Move the spring left or right until it is to the side of the score line between length and width panels of the case (At the Cutout). The amount of contact and position of the spring may vary depending on case thickness and construction.

6. In cases where a bottom spring under the Magazine is present, adjust the same as for the top spring.



Adjust the Case Plow (width) until pointer reads proper case width measurement.

Case Guides

Figure 18. Major Plow width adjustment Figure 19. Case Guide Ratchet Handles

Figure 18a.

Major Plow

1. Adjust the Major Case Plow assembly to the same width measurement used to adjust the Magazine. (See Crank Handle on bottom Figure 18 and 18a.)

2. Take the total height of the case with the bottom flaps closed and top flaps in the vertical position (up) and adjust the Top Hold Down Assembly to the proper height. (See crank adjustment handle at top of Case Erector Figure 22 and Figure 23.)

3. Take a case and fold in the bottom flaps and place it in the plow area. Adjust the Case Side Guide so that there is a slight pressure on the case. (See Figure 19.)

4. Adjust the Plows (Major and Minor) so that they are in the center of the case. 5. The Plows may be raised and lowered as necessary.



Adjust the Case Plow to the proper height and lateral position.

Figure 20. Fasteners for vertical adjustment Figure 21.

Place a case into the Plow Area and adjust Case Side Guide so that there is slight pressure on the case. Note: Repeat Guide Adjustment in the Discharge Area.

Figure 22. Adjust the upper hold down plate. Figure 23.

Ratchet Release for lateral adjustment.

Upper Hold Down Plate

DROP PACKER SYSTEM DESCRIPTIO SET UP


N AND

Adjust the Top Vacuum Cups by loosening respective mounting and rotating so that the body area of (not the flap) the case is grasped.


1. Turn the Vacuum Pump on by releasing the EMERGENCY STOP button on the

Operator Control Panel.

2. Adjust the top Vacuum Cups by loosening their mountings and rotating so that the largest amount of the case body is grabbed by the Vacuum Cups as shown in figures 24 and 25.

3. If the case is so small that the Vacuum Cup cannot contact it, use the factory supplied Manual Shut Off Valves to shut off vacuum and rotate the cup away from the case. The valves are mounted to the Vacuum Manifold that is on the opposite end of the guide rods bolted to the Vacuum Plate. Note that the lower vacuum cups are fixed. It is recommended that the upper vacuum cups be adjusted so that they contact the body of the case and not the upper flaps.

4. If larger cups are necessary, they will be applied only to the upper mountings.



DROP PACKER

SET UP PROCEDURE NOTE: In the following Set Up instructions, refer to the photos, and drawings on the following pages.

Set up the Case Erector as described in the previous case erector instructions.

Adjust the "T"- Rail to the center of the case, and adjust the outer Case Side Guide only, (opposite side of the lift cylinder) until the case is snug but not tight.

When changing over the Packing Head and installing new change part assemblies, the two (2) socket head bolts on the Drive Arms must be loosened. Then the Disconnect Pins can be removed by pulling them upward from the arm.

Cam Rollers on each side of the head ride on the inner side of the head support arms. The head can now be pulled forward and lifted out of the head support arms.

CAUTION: When moving Packing Heads to and from storage areas, the fingers, which guide the containers into the case during the drop, must not be damaged in any way. Never set the head down on the fingers; if it is necessary to place it on the floor, lay the packing head on end. Place a pack pattern of containers in the packing head against the stop blocks, depressing the flags. Position the photo eye to see through the flags, pull the containers back, one lane at a time, to check whether the photo eye functions. The indicator light on the photo eye will light when the photo eye is made. All lanes must be full to activate the indicator light.

With the packing head full, the bottle brake assembly can be adjusted. Adjust the assembly into its uppermost position. Place containers under the Bottle Brake Cylinder, with the Bottle Brake Cylinder in its retracted position, bring the assembly down until it is approximately 1/2" above the containers. Tighten all the adjustment knobs.


Description, Installation,

NOTE: Adjust the Air Pressure Regulator for the Bottle Brake Cylinder so that it will not crush containers. However, it should sufficiently hold back line pressure. The cylinder can be actuated manually by depressing the Override Button on the corresponding valve at the valve bank.

To adjust the Lane Guides, you must loosen the Quick Change Nuts on top of each Lane Guide. Start at the Packing Head end of the Conveyor. Move the guides to allow the containers to move freely in the lanes. The Lanes Guides must line up with the grids on the Packing Head to insure a smooth transition from the Conveyor into the Head. Check to be sure that there is proper clearance in the lanes (Approximately 1/16"-1/8"). Containers made of glass and metal having less clearance, and plastic containers having more. Please note that the Lane Guides on the in feed or Pusher end should be an additional 1/8" wider for ease of container entry. Some machines incorporate Lane Guide modifications that enable special products to be run. If your machine has been modified in this way, an addendum page will be inserted.

and Set Up Procedures: Page 24

Quick Change Nuts

Quick Change Nuts



(Agitators are optional) the adjustments to the Lane Guides and for the Agitators are done in a similar manner. The hex nuts on either side of the Cylinder Mounting Agitator Plate must be loosened and the Agitators adjusted in conjunction with the Lanes Guides. The Agitators can be further adjusted for the amount of movement past the side of the Lane Guides. The speed of agitation can be adjusted at the flow controls located at the Valve Bank. Please NOTE that the flow controls are factory set for proper operation.

With the case in the "T"-Rail as described earlier, the case lift can be adjusted for a specific case. The selector switch can be used to raise and lower the Case Lift.

CAUTION: If you are doing a change over from a tall to a short case, the case lift must be adjusted so that the "T"-Rail will not lift into the drop fingers. Doing so would damage the fingers. The Packing Head fingers should penetrate into the case approximately 1" past the score line. With the lift in the down position, adjust the height by loosening the Clamp Block on the shafts, repositioning and then re-tightening. After proper positioning is achieved, the Case Up Limit switch must be adjusted so that it is actuated when the lift is up.



Drive Arm

Stop Block

Drive Arm

Disconnect

Tie

Cam Roller

Figure 26. Packing Head Assembly

Side view

Cam Roller

Cam Roller

Quick Change Bolts

Photo Eye

Flag

Cam Roller

Packing Head Assembly view



Trip Limit Switch

Plate Limit T Rail / Case Support Plate

Lane Guide Lane Guide

Figure 27. Case Lift Assembly

Case Lift Assembly view



Figure 27a. Side view of Case Lift Assembly

Quick Release for lateral positioning

Track for raising and lowering

T- Rail and Case Lift view.



Bottle Brake Air Regulator

Bottle Brake Cylinder Bottle Brake

Cylinder

Figure 27b. Bottle Brake

Bottle Brake Assembly view



Bombay

Figure 28. Bombay “Fingers”

Bombay View



TBS100FC CASE SEALER CONTROL PANEL

EMERGENCY

STOP SEALER START

SEALER STOP

SEALER JOG

NOTE: SOME PANEL LAYOUTS AND SWITCH LABELS MAY VARY SLIGHTLY FROM MACHINE TO MACHINE.

IF SEALER IS PURCHASED WITH ERGOPACK, LOADER, OR PACKER PUSHBUTTON PANEL WILL BE INCLUDED WITH SPECIFIC MANUAL.

1. “EMERGENCY STOP” - Red “mushroom” button. Push in for Emergency Stop.

Twist and pull out to reset.

2. “SEALER START” - Green pushbutton (sometimes illuminated) starts the sealer.

3. “SEALER STOP” - Red pushbutton stops the sealer.

4. “SEALER JOG” - Black pushbutton that moves drive conveyor to first position.



TBS100FC CASE SEALER MACHINE ADJUSTMENTS

CAUTION:

BEFORE ATTEMPTING TO SET UP OR CHANGE OVER THE TBS100FC SEALER, BE SURE THE EMERGENCY STOP BUTTON HAS BEEN DEPRESSED.

Warning! Carefully follow the Combi installation and set up procedures. The manufacturer will not be responsible for damages caused by improper installation and set up.

A. Bottom Case Adjustable Support

Taper

1. Using the adjustment handle, adjust the bottom taper supports so they are centered on the

case. See Figure 29.

Bottom Taper Adjustment Handle (notice V-shaped bars connected to handle)

TBS100FC Emergency Stop

Figure 29. Adjustment Handle.

Gluing (If applicable)

2. Using the adjustment handle, adjust the bottom rail supports so they are centered on the case.



CASE SEALER MACHINE ADJUSTMENTS CONT.

B. Upper Assembly Adjustments

1. Record case height without flaps. Adjust the upper assembly so that the case with the minor

flaps folded horizontal can slide under the front minor flap plow. (See Figure 30.) Adjust the upper assembly with the adjustment handle located at the top of the mast, which supports the upper assembly. (See Figure 31.) Turn the adjustment handle until the scale points to recorded case height (without flaps) and add 1/8” (to allow 1/8” gap between the top of the case and the plow.)

Case

Case with minor flaps folded should be able to slide under this plow with a gap of 1/8” between the top of the case and the plow.

Figure 30. Front Minor Flap Plow.

Adjustment Handle for Upper Assembly with scale on side support.

Figure 31. Adjustment Handle for Upper Assembly.



CASE SEALER MACHINE ADJUSTMENTS CONT.

Upper Assembly Adjustments Continued

2. Loosen the locking handles and adjust the upper assembly so the front minor flap plow is located at the center of the case. (See Figure 32.)

Loosen these two locking handles and adjust left or right in order to center the front minor relation to the center of case.

Figure 32. Locking Handles To Center Front Minor Flap Plow and Tape Head.

3. Position the pneumatic switch valve to the leading edge of the case. (May have to adjust each time there is a new case size.) This pneumatic switch actuates the rear kicker. The rear kicker drops down to close the rear upper minor flap on the case. The rear kicker should be adjusted so that the rear upper minor flap is closed before it slides under the minor flap plow. The kicker should stay down until the rear flap is captured by the plow. (See Figure 33 and 34 on next page.)



CASE SEALER MACHINE ADJUSTMENTS CONT. Upper Assembly Adjustments Continued

Pneumatic Switch Valve that actuates the Kicker when leading edge of case reaches this white tube.

Handle to adjust position of Pneumatic Switch Valve.

Direction of case movement

Figure 33. Pneumatic Switch Valve That Actuates Rear Kicker.

Rear Kicker will drop down to hold rear minor flap in horizontal position until rear minor flacaptured by the plow.

p is

Plow

Figure 34. Rear Kicker in Suspended Position.


Descriptio


4. Adjust the case side compression roller to hold the case so that the major flaps are held together during compression. See Figure 36.

5. (If equipped with Hot Melt Sealing) - The location of the glue gun actuators should not need adjusted, but the glue timers need to be adjusted depending on case size.

6. The rear flap kicker can be adjusted in relation to the plow, if necessary. (This will be necessary if running extremely long cases.) See Figure 34.

Random Indexer Valve that actuates the Random Indexer. Can be adjusted

Figure 35

Random Indexerwill raise and hold next case back.

n, Installation, and Set Up Procedures: Page 36

by unlocking handle and moving into position depending on case dimensions. The random indexer will rise up to hold next case out of sealer area until current case has reached desired position.

. Pneumatic Switch Actuates Random Indexer.




7. Loosen clamp handles in order to adjust the lateral (or side to side) position of the taping head and plow for machines with a top taper. See Figure 32. Place an erected case in the machine and jog the belts until the case is under the upper tape head. Crank the taping head to the desired position. Tighten the clamp handles. For machines with a bottom only taper, adjust the top hold down guides to their appropriate height.

Upper tape head

Compression roller handles

Photo Eye

Case side compression rollers.

Figure 36. TBS100FC overview with upper and bottom taper.



C. Belt Drive Adjustment

Adjust the drive belt sides to accommodate the desired case.

Inner belt drive is fixed and cannot be dj t d

Outer Belt Drive.

Pins for adjustments

Figure 37. Side Belts

The inner belt drive (0 line) is fixed and cannot be horizontally adjusted. The outer belt drive is horizontally adjustable. If adjustments are needed, move outer belt drive so case is secure against side, but not tight. Using the adjustment handle, adjust the belt drive assembly to accommodate the desired case.

NOTE: ALL ADJUSTMENTS ARE TO BE USED AS A GUIDELINE FOR

INITIAL SET-UP. THESE ADJUSTMENTS MAY HAVE TO BE CHANGED AFTER ACTUAL RUNNING CONDITIONS ARE ACHIEVED. EACH PRODUCT IS DIFFERENT, AND MACHINE MUST BE ADJUSTED ACCORDINGLY.



SEQUENCE OF OPERATION

Drop Packer

NOTE: Before machine is operated, the correct setup for all the equipment in the packaging system must perform to assure smooth operation of the machinery.

1. Turn the Cycle Selector to the ON position. (Cycle Off is for manual operation of

the machinery.)

2. Make certain that the Case Lift, the Head Shift, are in the Auto mode. (The other modes for these two selectors are for manual operation only.)

3. Release the Emergency Stop button and press the Loader Start Button, the solenoid

valve (main air) will energize.

4. Push Erector Start Button. CAUTION: If the Case Erector (CE) is not in the home position, it will automatically return and start the erection cycle. The case erector will erect the initial case. (Switch will illuminate Green.)

5. Push the Call for Case Button. The C.E. will transfer the case onto the T-Rail

Assembly and erect the second case.

6. The Drop Packer is ready to operate.

7. Turn the Transfer Conveyor, Product Conveyor, and Agitator selectors to the start position.

8. The product will travel down the Transfer Conveyor and start to fill the lanes in the

packing head. 9. When the product adequately fills each lane, and make the Packing Head full photo

eye, the case lift will automatically rise. The bottle brake clamps the product in the lanes, preventing extra product from filling the head while it is shifting.

10. The head will shift, dropping a pattern of product into the case.

11. The machine can be manually jogged through the stages of the Drop Packing Cycle by placing the Cycle selector switch to the Off position and setting the Head Shift and Case Lift switches to Manual mode.



SYSTEM SEQUENCE

Figure 39.

1. Flat case in magazine. 2. Case is extracted from magazine and initially formed by Squaring Arm. 3. Rear Minor Flap is folded in 90°. 4. Case moves and Front Minor Flap folded in 90°. 5. Major Flaps forced across plows and folded in 90° to horizontal. 6. Case is picked up by Auxiliary Pusher and pushed across to packing area. 7. The product will travel down the Transfer Conveyor and start to fill the lanes in the

packing head. As the lanes fill up, the Agitators will allow the lanes to fill evenly. 8. When the product adequately fills each lane, and make the Packing Head full photo

eye, the case lift will automatically rise. The bottle brake clamps the product in the lanes, preventing extra product from filling the head while it is shifting.

9. The head will shift, dropping a pattern of product into the case. The case lift will remain in the up position until the packing head fills with the second layer for the case. The head will shift again, dropping the second layer of product into the case. The lift lowers, and a new case is called for.



10. The machine can be manually jogged through the stages of the Drop Packing Cycle by placing the CYCLE selector switch to the OFF position and setting the HEAD SHIFT and CASE LIFT switches to MANUAL mode.

11. The case, when presented to the sealer, is guided through the machine by belts located on both sides of the case. The leading edge of the case actuates a pneumatic switch which energizes the rear minor flap kicker. A plow is simultaneously closing the front minor flap. The major flaps are then plowed closed.

12. The case enters the taping head where tape is applied. Tape can be applied top and bottom or top only to the case.

13. The cycle is then repeated.



IMPORTANT INFORMATION

TOUCHSCREEN PROCEDURES Before touching screen, begin by pressing E-Stop and then Safety reset. When Auto Start is pressed, everything is started up, beginning with case sealer first and then working way back to case erector. (Will keep making cases until it is satisfied (tries 4 times). Will run automatically in this mode. If problem with product go to maintenance screen: Lock doors closed button or Lock lift up button – both will put machine in automatic but it will stop at point you choose on button – so you can observe necessary step. Once the problem is corrected, operator must go to machine and hit the auto start push button (this is the only choice – no button on touchscreen will start machine up again). Training Tool If want to watch each step with manual control so can stop and look at each step the operator has some options on the touchscreen where normal safeties still apply. On Maintenance screen choose CE CYCLE STOP MODE or LOADER CYCLE STOP MODE. Cycle Step screen

1. CE Step Cycle Start – start cycle 2. CE Step Cycle Stop – stop cycle 3. CE Step Cycle pushbutton – one step of cycle (keep hitting after each completed step to

watch step by step). If without a case need to choose case present bypass push button so you can bypass the safeties. Loader Step Screen

1. Loader Step Cycle Start – starts one part of the cycle and then stops 2. Loader Step Cycle Stop – stop cycle 3. CE Step Cycle push button – one step of cycle (keep hitting after each completed step to

watch step by step). If without a case/product need to choose head full bypass push button so you can bypass the safeties. Once you have cases where and when you want them, the operator must stop both CE and Loader (Cycle stop) and go to machine and hit auto start. Picks up right where it operator left the cycle. The machine does not home first. Manual Control (not automatic) Before touching screen, begin by pressing E-Stop and then Safety reset. From maintenance screen, choose manual screen. Choose part you’d like to control (such as bottle brake up, etc,).



Photo Eye Photo eye at end of transfer conveyor. Photo eye at end of discharge conveyor. Discharge backup photo eye standard procedure – once a discharge backup photo eye senses the cases, the sealer will continue to run cases until it receives a “case present” photo eye on the transfer conveyor. Then the transfer conveyor will stop and enter disable mode. The “call for case” message will appear on touchscreen.

Documents

DROP PACKER SYSTEM DESCRIPTION AND SET UP