Sealer Closer-Instruction manual

7/30/2019 Sealer Closer-Instruction manual

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1492LS09.DOC OPERATION AND MAINTENANCE

SAPACSEALERCLOSERMODEL41B

DFA-EL PASOOPERATION AND MAINTENANCE MANUAL

CONFIDENTIALITYThis document contains information, which is valuable and confidential to

Colby Powder Systems Pty Ltd (Colby) and Colby Systems Ltd (Sapac)and is intended for disclosure to and use by the intended reader only.

It is a condition of supply of this document that the reader may notwithout the prior written consent of Colby Powder Systems

(a) Copy or reproduce any part of this document, or(b) Disclosure any part of this document to another person.

PROJECT NO: 1492

SERIAL NO: LS09

DOCUMENT REF: 1492LS09

CUSTOMER: DAIRYFARMERSOFAMERICA

AUTHOR: M.W.

EDITION NO: 1

DATE: 30-04-01


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Read this manual completel before starting-up oroperating this equipment.

Be certain all personnel concerned with this machineryare fully alerted to the possible hazards of the equipmentand its utilities (electrical & pneumatic) before anyoperation is allowed.

Colby accepts no liability for any claims with regard to equipmentdamage, personal injury, death or incurred costs caused by the improperinstallation, operation or maintenance of the supplied equipment.

The information contained in the manual is accurate at the time ofwriting, however Colby reserves the right to make improvements to theirproducts, to benefit the end-use, without notification.

All rights are reserved with respect to Patents, Designs and Copyrights.


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PREFACE

This Operation and Maintenance Manual has been prepared by ColbySystems for Dairy Farmers of America, El Paso.

When making inquiries, please quote the Colby project number #1492and the project designation, - Powder Handling and Packing.

The purpose of this Manual is to provide data for the proper operationand maintenance of your SAPAC equipment.

The instructions given in this manual are mandatory for the correctoperation and maintenance of the SAPAC machines supplied.

For warranty claims, please refer to the Colby standard WarrantyTerms and Conditions.

Colby Systems Ltd.(Sapac)

30 Sir William Avenue

Greenmount Phone: +64-9-274 9554

Auckland Fax: +64-9-274-6488

New Zealand E-mail: [email protected]
mailto:[email protected]:[email protected]


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TABLE OF CONTENTS

1. Revision Control Sheet .................................................................................... 1-1

2. Scope and Intended Reader ............................................................................ 2-1

2.1. Scope ........................................................................................................ 2-1

3. Abbreviations and Definitions ....................................................................... 3-1

3.1. Abbreviations ......................................................................................... 3-1

3.2. Definitions............................................................................................... 3-1

4. References ......................................................................................................... 4-1

5. Safety .................................................................................................................. 5-1

5.1. Packaging - Commitment to Safety ..................................................... 5-15.2. General Safety Procedures.................................................................... 5-1

5.3. Safety Precautions .................................................................................. 5-2

6. Start up And Operation................................................................................... 6-1

6.1. Introduction ............................................................................................ 6-1

6.2. General Arrangement ........................................................................... 6-2

6.3. Operating Instructions .......................................................................... 6-3

7. Control System ................................................................................................. 7-1

7.1. Introduction ............................................................................................ 7-1

7.2. The Switch Buttons and Indicator Lamps .......................................... 7-2

7.3. The Temperature Controller ................................................................ 7-5

8. Leveller And Cleaner ...................................................................................... 8-1

8.1. Leveller .................................................................................................... 8-1

8.2. Cleaner Section ....................................................................................... 8-4

9. Heat Sealing ...................................................................................................... 9-1

9.1. Seal Heating ............................................................................................ 9-1

9.2. Seal Compression ................................................................................... 9-5

9.3. Seal Scoring ............................................................................................. 9-69.4. Seal Compression/Scoring Wheel Adjustment ................................. 9-7

9.5. Seal Cooling ............................................................................................ 9-8

10. Bag Top Closer Section .................................................................................. 10-1

10.1 Bag Top Closer ..................................................................................... 10-1

10.2. Bag Top Compression ......................................................................... 10-5

11. Conveyor ......................................................................................................... 11-1

11.1. Introduction .......................................................................................... 11-1

11.2. Conveyor Specifications ..................................................................... 11-1

12. Electrical .......................................................................................................... 12-1

13. Pneumatics ...................................................................................................... 13-1


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13.1. Pneumatic Lubrication (For machines with airlinelubrication) ............................................................................................ 13-1

13.2. Pneumatic Schematic........................................................................... 13-3

13.3. Pneumatic Components ...................................................................... 13-3

14. Troubleshooting & Maintenance ................................................................. 14-1

14.1. Levelling Mechanism .......................................................................... 14-1

14.2. Levelling Mechanism .......................................................................... 14-3

14.3. Cleaner Mechanism ............................................................................. 14-4

14.4. Heating Dies ......................................................................................... 14-6

14.5. Seal Compression Wheels ................................................................... 14-7

14.6. Seal Scoring Wheels ............................................................................. 14-9

14.7. Seal Compression/Scoring Wheels Drive Chain .......................... 14-10

14.8. Bag Top Closer ................................................................................... 14-11

14.9. Air Heating Element.......................................................................... 14-12

14.10. Drive Train .......................................................................................... 14-15

14.11. Carrier Belts ........................................................................................ 14-22

14.12. Conveyor ............................................................................................. 14-26

15. Spare Parts ...................................................................................................... 15-1

15.1. Spare Parts Requirements ................................................................... 15-1

15.2. Illustrated Spare Parts ......................................................................... 15-2

15.3. Essential Spare Parts .......................................................................... 15-1815.4. Recommended Spare Parts ............................................................... 15-19

16. Appendix A..................................................................................................... 16-1

16.1. Pneumatic Circuits .............................................................................. 16-1

Authorised by : .................................................... Date : ...........................................


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1. Revision Control Sheet Pa e 1 of 1

1. REVISION CONTROL SHEET

Revision

Edition 1 30/04/01 Mark Winter

All sections New document


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2. Scope and Intended Reader Page 1 of 1

2. SCOPE AND INTENDED READER

2.1. Scope

This document is the operating manual for the Sapac Sealer Closer Model 41Bmachine and its associated controller system. It is directed to the personnelinvolved in both the day-to day operation of the machine, and the diagnosisand correction of faults. It also provides information on the mechanicalmaintenance of the machine. Some electronic details are included forconvenience. More detail, particularly on the controller is contained in theelectrical/electronic operators manual.


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3. Abbreviations and Definitions Page 1 of 1

3. ABBREVIATIONS AND DEFINITIONS

3.1. Abbreviations

A-B Allen Bradley

Ack Acknowledge

C/B Circuit Breaker

CC Control cabinet

D/A Double Acting (cylinders)

E-Stop Emergency Stop

I/O PLC Inputs and Outputs

N/C Normally Closed

N/O Normally Open

P&ID Process and Instrumentation Drawing

P.B Push Button

PE Photo Electric Switch

PLC Programmable Logic Controller

PX Proximity Switch

RF Radio FrequencyRIO Remote Inputs and Outputs Link

SCADA Supervisory Control Advisory and Data Acquisition

TOL Motor Thermal Overload

3.2. Definitions

Colby Colby Systems Ltd.

Sapac Colby Systems Ltd


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4. References Page 1 of 1

4. REFERENCES

.1. This document refers to:-

Document Type Name Description Revision

Sapac Manual 25/2 Rotary Packer Operation and MaintenanceManual

1

Sapac Manual Bag Loader Operation and Maintenance 1

Sapac Manual Neck Stretcher Operation and MaintenanceManual

1

Sapac Manual Sealer Closer Model41B

Operation and MaintenanceManual

1

Sapac Manual Electrical/ElectronicOperator

Electrical/Electronic OperatorsManual

1


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5. Safety Page 1 of 3

5. SAFETY

5.1. Packaging - Commitment to Safety

Colby is committed to supplying Packaging Systems that provide a safeworking environment for your company.

However, safety also requires a continuous commitment from you, in theproper use, operation and maintenance of all the equipment supplied.

It is important that operating and maintenance personnel be instructed inrecognising hazards and relevant safety procedures.

Staff should be encouraged to report any accident, no matter how minor, sothat its effect on safety can be immediately assessed. The realisation that they

could suffer injury is often a powerful incentive to their observance of this, butit would help if you, as the employer, can be seen to take notice of theirreports and have serious faults rectified immediately.

Colby recommend the Standards contained within this section beimplemented and used by you.

5.2. General Safety Procedures.

As the customer, it is your responsibility to establish a maintenance program,which ensures that all equipment is kept in a safe condition. For each piece ofequipment supplied by Colby, details of the maintenance requirements can be

found in the relevant section of this manual.

IMPORTANT - Read this NOW

The following conventions are used in Colby manuals:

Warning: This symbol means that people may be injured ifthe procedures are not followed.

Caution: This symbol means that equipment may be damagedif the procedures are not followed.

.1. All maintenance must be carried out by trained personnel.

.2. Only trained Employees shall be permitted to operate equipment.

Training shall include instruction in operation under both normal andemergency conditions.


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.3. This equipment comprises of Electro-mechanical devices, which are

capable of unexpected motion. Where possible steps have been takento guard this equipment through the use of physical as well aselectronic safety features without inhibiting its function. Howevercertain safety practices need to be followed to minimise the inherentdangers associated with any Electro-mechanical device.

5.3. Safety Precautions

Following is a list of recommendations for your guidance and safety. Thesemust be adhered to at all times.

Further, more specific, safety recommendations are listed at other relevant

locations throughout this manual.

We recommend that you incorporate the following safety precautions and thismanual as part of your Companys Safety documentation system.

Read this manual completely before starting-up or operatingthis equipment.

Serious injury and/or equipment damage could result fromimproper operation of this equipment and not heeding all

safety recommendations Only suitably qualified and trained personnel should operate

and maintain this equipment

Be certain all personnel concerned with this machinery arefully alerted to the possible hazards of the equipment and itsutilities (electrical & pneumatic) before any operation isallowed

Determine the location of all emergency stop devices andair/power isolators (disconnects). When the air or powersupply isolators are switched off a lockable hold card or

similar system should be employed so that air or power is notreconnected until the equipment is in a safe and satisfactorystate.

Disable the machine by isolating (disconnecting) and lockingair and power supply to the equipment before attempting anycleaning, maintenance or manual testing of components. Beaware that on machines that have heating devices these maybe hot for some time after the power has been removed.

Be sure all guards are in place and observe all warning signs.Do not remove or open guards while the machine is running


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There will be occasions when the machine stops because of afault condition. When the fault clears the machine may start

again without warning. Remain well clear of the machine at alltimes while in operation.

Never start equipment without first checking that looseobjects, tools and all personnel are clear of the machinery.

All personnel in the immediate area of the equipment shouldbe alerted prior to stating.

Observe extreme caution when switches are turned on andthe equipment is operational. Do not attempt to beat themachine by reaching into areas where there are moving orhot parts.

Ensure that the machine and all electrical equipment is free ofany accumulation of water, dust or other contamination.

Do not open junction boxes or control panels unless you area qualified electrician. Be sure power is isolated. Except whenelectricians are performing maintenance, electricalenclosures and junction boxes should always be securelyclosed.

The EMERGENCY STOP is a large red illuminatedpushbutton-labelled EMERGENCY STOP. Some equipment

is also fitted with a red emergency stop pull-wire. Both typesof emergency stop devices are latching so once theemergency stop device has been activated it will remain inthat state until it is reset (or unlatched)

When pressed the Emergency Stop button/wire willdisconnect all output control voltage. Be aware that onmachines with heated surfaces these may remain hot forsometime after the Emergency Stop has been activated.

Never rely on the Emergency Stop to isolate a machine.Isolation of equipment must be performed using the main air

and power isolators (disconnects)

Never reset the Emergency Stop if someone else has left iton.

Before unlatching the Emergency Stop and restating themachine ensure that all personnel, tools and other equipmentare clear of the machine and that it is in a satisfactory state tobegin operation


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6. Start up And Operation Page 1 of 8

6. START UP AND OPERATION

6.1. Introduction

The Sapac Sealer Closer basically comprises of four sections. These sectionsare covered in detail in this manual (sections 8 to 10). Further details onelectrical pneumatics and spares are covered in their own separate sections.

6.1.1 The purpose of the Sapac Sealer Closer is to:

Accept a bag which has been neck stretched and deaerated (usuallyby the Sapac Bag Presenter), into the levelling section.

Level the bag top to allow re-activation further on in the machine.

Clean the seal area of any contamination, which may affect sealintegrity.

Heat-seal the inner liner through the outer paper plys.

Score the inner liner to release it from the paper outer.

Compress the still plastic liner seal to ensure a hermetic seal.

Cool the sealed liner (and paper) to provide a strong seal before anyload is applied to it in subsequent handling after the machine.

Reactivate the pre-applied hot melt adhesive and close the topstepped end of the bag.

Compress the reactivated top of the bag to ensure secure adhesion tothe paper.

The entire Sealer is controlled by a PLC, which provides outputs to thesolenoid valves, which perform the sequencing functions. Most of theseare pneumatic valves acting directly from the output. There is nopneumatic logic as such involved.

The PLC also receives inputs from the various sensors on the machinewhich act to identify the status of the bags being processed and theoverall machine status.


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6.2. General Arrangement

Figure 6.2 Right to Left Feeding Machine


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6.3. Operating Instructions

6.3.1. Start Up

Ensure that the mains isolator (disconnect) at main control cabinet isswitched to the ON position and that the Emergency Stopilluminated push button on the operators control panel is unlatched.

Select the Sealer Heat and Closer Heat illuminated selector switchesto ON.

Depending on whether or not the product being packed requires theliner seal area cleaned select the required function at the Bag SealCleaner switch (OFF/ON).

Assuming that the packed bags are required to be closed as well as

sealed, select this function also by turning the Bag Top Closer Flapilluminated selector switch to DOWN.

Note: While the heating zones are below their operating temperature envelope (10units either side of set point) the Sealer Heat Alarms (red indicator lampsunder each zone controller) will remain illuminated.

The sealer up to heat condition is indicated when the Zone AlarmLamps are extinguished and the Drive/Conveyor Start/Stop

illuminated push button switch may now be operated to make themachine operational.

Note: We recommend that whenever the Sealer Heat Switch is selected to ON (afterhaving been switched off) that a Seal/Closure test be carried out on an emptybag prior to full line start-up.

While performing the above seal test, a good opportunity exists tocheck that the Sealer Carrier Belt speed is synchronised with theconveyor speed below i.e. as the test bag leaves the leveller section,keep a visual check on the bag bottom speed compared to theconveyor speed.

Should the carrier belt speed appear to need adjustment, refer toOperator Adjustments below.


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6.3.2. Operator Adjustments

Operator Adjustment of the carrier belt speed may be necessary

should there be a change to line speed.The Sealer/Closer Frequency Drive Speed control adjuster is acalibrated dial with level lock to prevent accidental adjustment. Theadjuster is located in the top left-hand corner of the Low Voltageelectrical cabinet beside the Motor Overload reset switch.

To synchronise the carrier belt speed with that of the bag conveyorfirst feed an empty bag into the leveller section being careful to ensurethat it is within the admissible levelling height.

As the bag exists the leveller section, mark the conveyor belt at thebottom leading edge of the bag so that the relative distance between

bag edge and mark can be monitored. If a gap opens up between themark and the bag edge (mark edging), then the carrier belts aremoving slower than the conveyor belt. If the bag edge overtakes themark then the reverse is true.

To speed up the carrier belts, release dial lock of the speed adjusterand turn dial clockwise until desired increase in speed is achieved. Toslow down the carrier belts, release the dial lock and turn dial anti-clockwise.

Note: Precise synchronisation can not be achieved in one adjustment, however aslong as relative speeds are close enough, fine tuning can be achieved duringnormal running.

6.3.3. Bag Presentation

All bags must enter the machine at the correct height for the levellingsystem to operate correctly.

A legend plate is located on the outside of the first bulkhead. Thisshows the minimum and maximum height that the extreme top edgeof the bag must fall within so that efficient processing through themachine is ensured.

See Figure 6.3.3 below.


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MAX.

BAG HEIGHT

MIN.Figure 6.3.3 Bag Height Label

Note: 1. It is important that the right size bags are in use for the product being packedie. If the bag is too small, then there will not be enough head space (above theproduct) for the bag to be transported through the machine which will result inregular jam-ups and/or bag damage.

Similarly if the bags are too big, then this could cause the bag to entrapunwanted air above the product resulting in unstable pallet stacks.

2. The nominal headspace requirement prior to neck stretching betweenproduct and bag top is 250mm (10 inch).

6.3.4. Machine Height

To make a downward height adjustment of the machine, place atypically filled bag on the conveyor prior to the Neck Stretcher (BagPresenter) and start the line.

When the bag enters the leveller section it will be stopped by theawaiting Bag Stop Arm. The operator should immediately stop theSealer Drive/Conveyor via the control panel. If electric heightadjustment has been provided as an option, it will be necessary to usethe UP/DOWN momentary contact selector switch on the operatorscontrol panel, otherwise the height adjustment is made via thehandwheel provided on top of the machine pedestal.

The operator can now adjust the machine height downwards lightlycompressing the head space in the bag so that the leveller sectionundercarriage is lighting pressing down on the product and its bag.


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Note: Final operating height is obviously dictated by the ease of passage of filled

bags through the machine.

The Sealer can now be started up again and the test bag can be driventhrough the machine in the normal manner.

Note: Prior to switching on the packing machine and going to full line automationthe following requirements should be checked according to precedinginformation.


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6.3.5. Line Start-Up Check List

Is the bag the right size for theproduct being packed?

No Source right size bag.See Section 6.3.3.

Yes

Is the Sealer set to the rightoperating height?

No Make adjustments.See Section 6.3.4.

Yes

Are the carrier beltssynchronised with the bagconveyors?

No Synchronise Carrier BeltSpeed. See Section 6.3.2.

Yes

Are the heating zones up totemperature?

No Wait for alarm lamps toextinguish.

Yes

Has a satisfactory seal testbeen done since the machinewas last shut down?

No Do Seal/Closure Test.See Section 6.3.1.

Yes

Is the downline equipment allactive so that line controlinterlocks are operational?

No Remedy prior to starting upPacking Machine.

You are not free to carry outthe Packing Machine Checksprior to running the line inautomatic mode.


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Line Start-Up Check List cont

Provided that the Sealer/Line preparation has been carried out as per

preceding pages, when filled, the Neck Stretched deaerated bags willenter the Sealer Carrier Belt nip pulleys and be gripped by thecarrier belts and fed up to the Bag Stop Arm. The Levelling ClampRollers will quickly separate the drive belts and immediately drivedown the bag top until the leveller photo-eyes are uncovered.

The Bag Stop Arm will now withdraw allowing the Bag to proceedthrough the machine and on down the line.

Note: The following Sections 8, 9, & 10 outline the mechanical adjustments that maybe necessary from time to time for fine tuning the machines performance.


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7. Control System Page 1 of 6

7. CONTROL SYSTEM

7.1. Introduction

The Sealer/Closer control system is arranged in three sections - the HIGHVoltage control section, the LOW Voltage control section and the OperatorsControl Panel/ Cabinet.

The HIGH Voltage section of the Control System is located in a lockableelectrical cabinet which is fitted with a mains ISOLATOR/DISCONNECT, forisolation of all power to the machine. The thermal overloads, fuses and powercontactors that control the motors in the field are also located in this cabinet.The frequency drive that controls the Sealer Drive and the switchingcontactors for the Sealer/Conveyor motors are located in the high Voltagecabinet. All precautions stated by the frequency drive manufacturer must beobserved when working on any Variable Frequency drive.

In the LOW Voltage section of the Control System is the Allen Bradley 500programmable Logic Controller. All LOW Voltage Control is accomplishedusing 24 Volts AC. All control switches and outputs are on 24 Volts ACsupply while inputs, some lamps and temperature controller outputs, are on24 Volts or less DC supply. The function of the PLC is to monitor variouscontrol switches and field sensors and with the use of the Ladder Logic,sequence the machine in a logical and safe manner. Since any automatedmachinery is totally reliant on the feedback from the various switches andsensors, it is important that these are not tampered with in any way and thatthey are checked and maintained on a regular basis. The switches and sensorsmay only be adjusted by a qualified Technical Engineer.

There are basically four main sections of control: the Leveller, Cleaner,Heating and Closing sections.

Refer CAL 3200 Temperature Controller Operation, in the Appendix, for setup

procedure on the Heating Sections.

Warning:

After Power Off, it is possible for the Variable Frequency Drive tohave dangerous residual voltages present for up to 30 minutes.

Extreme care must be exercised when working with VariableFrequency Drives. For total isolation of mains supply to thesystem, the lockable Mains Isolator located on the ElectricalCabinet must be turned off and locked for total safety.


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7.2. The Switch Buttons and Indicator Lamps

All Control Buttons and indicators are located on the control panel of thecontrol cabinet on top of the Sealer Spine. Please refer to the Control Panellayout drawing Figure 7.1.11 for reference.

7.2.1. Drive/Conv. Stop/Start Flush P.B. Switch (Green)

The Start/Stop switch is a momentary contact illuminated pushbutton switch which switches via the P.L.C. Ladder Logic from stopto start to stop on alternative operation. When switching from STOPto START it enables the Sealer Drive/Sealer Conveyor to start-up andrun (interlocks permitting) via main contactor No.6 in the HighVoltage Section of the Main Control Cabinet.

7.2.2. Emergency Stop Latching Mushroom Button Switch (Red)

The Emergency Stop switch is an illuminated large mushroombutton labelled EMERGENCY STOP and is provided to allow themachine to be stopped immediately in the event that injury topersonnel or damage to componentry is imminent. When this buttonis pressed, all machine control voltage is aborted without delay, thuspower is removed from all control P.L.C. outputs. The EMERGENCYSTOP button is self latching when pressed and must be pulled out to

release. Extreme care must be exercised to ensure that all personnelare clear of the machine before releasing the EMERGENCY STOPbutton. A red indicator integrated in the button is illuminatedwhenever the EMERGENCY STOP is activated. NEVER release theEMERGENCY STOP if someone else has left it latched on.

Once you have activated the EMERGENCY STOP button, ALWAYScheck with all other personnel working on the machine beforereleasing it, and then make them aware that the machine has beenreturned to its normal operating conditions, ready for start-up.

7.2.3. Sealer Heat OFF/ON Selector Switch (Black)The Sealer Heater Selector Switch is a plain maintained two positionswitch which, when switched to ON, allows the TemperatureControllers to bring the heating zones up to set-point temperature viamain contactor No.4 in the High Voltage section of the main controlcabinet.

7.2.4. Closer Heat OFF/ON Selector Switch (Black)

The Closer Heat Selector switch is also a plain maintained two

position switch which, when selected to ON, interacts with the CloserAir Pressure switch (via P.L.C. output) to allow the Closer heatingzone to come up to set point temperature by switching Main


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Contactor No.3 in the High Voltage section of the main controlcabinet.


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7.2.5. Seal Heat and Closer Alarm Indicator Lamps (Red)

The Heat Alarm indicator lamps are powered by incandescent bulbsvia the Temperature Controller alarm outputs which are programmedto give both over and under temperature conditions.

7.2.6. Bag Sealer Cleaner OFF/ON Selector Switch (Orange)

The Bag Seal Cleaner switch is a two position illuminated selectorwhich when switched to the OFF position negates the Bag Liner sealarea cleaning operating via the P.L.C. Ladder Logic programme.When turned to the OFF position the selector switch illuminates itsindicating lamp so as to draw the operators attention to the fact that

the Sealers normal operating attitude has been comprised.

7.2.7. Cleaner Error/Batch Complete Indicator Lamp (Orange)

The Cleaner Error indicator lamp doubles as the Batch Completeindicator i.e. when indicating a Cleaner Error the incandescent bulbflashes from OFF to ON and is simultaneously accompanied by anaudio alarm. When indicating the Batch Complete Condition theincandescent bulb is illuminated steady accompanied by a continuousaudio alarm for a 5 second period.

7.2.8. Sealer Height Up/Down Selector Switch (Black)

When fitted, the Height Up/Down switch is a mid-position off, threeposition switch with one momentary contact each for the up anddown travel of the Sealer Spine. When operated in either positionmain Contactor No.s 8 or 9 are energised to operate the geared motorattached to the top of the machine pedestal.

7.2.9. Bag Top Closer Flap Up/Down Selector Switch (Orange)

The Bag Top Closer Flap switch is a two position illuminated selectorwhich when selected to UP, lifts the flap via solenoid valve andpneumatic cylinder. Its purpose is to prevent the re-activation of thepre-applied glue at the bag top OR to avoid folding over the top of thebag when one bag is being put through the machine repetitively aftereach subsequent seal has been cut-off the bag top for inspection.When the switch is turned OFF, its indicator lamp illuminatescontinuously. The purpose of this is to indicate that the normaloperating attitude of the machine has been compromised.


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7.2.10. Downline Fault Indicator Lamp (Red)

The Downline Fault Indicator Lamp is powered by an incandescent

bulb which is illuminated steady when a downline interlock goesfalse normally resulting in the prevention of further filled bags beingprocessed by the Sealer.

7.2.11. Control Panel

Figure 7.1.11 Control Panel

7.3. The Temperature Controller

There are three (3) CAL 3200 Temperature controllers in the 41A SealerControl Panel, each controlling one (1) Temperature Zone see figure 7.2below.

In the Heat Sealing Section (Section 9 of this manual) there are three (3) zoneseach comprised of one (1) pair of Heating Dies, these are Zones 1 to 3.

In the Bag Top Closer Section (Section 10 this manual) there is one (1) Zonewhich controls the Air Heater Element Zone 5.


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Figure 7.2

Operator Adjustment

View setpoint

Increase setpoint

Decrease setpoint

To reset alarm or fault message

Momentarily press together

Note: Ex Factory Setpoint for Zones 1-3 is 2200C (4300F) and Zone 5 is 2300C (4450F)


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8. Leveller And Cleaner Page 1 of 5

8. LEVELLER AND CLEANER

8.1. Leveller

8.1.1. Bag Stop Arm Operation

The Bag Stop Arm is used to skid the base of the bag on theconveyor belt while levelling takes place.

The most critical setting on the Stop Arm is its height. This is usuallyabout 250mm (10 inch) to 300mm (12 inch) to the paddle centre fromthe top of the conveyor belt.

Essentially, the arm should always be against the vertical part of thebag, as this is consistent in position. If the arm is against the flared out

toe of the flat tube bag, the position of the bag bottom will vary.This will cause the bag top to keep moving after the bottom hasstopped and tend to tip the bag forwards.

The sketch below shows the correct position of the stop arm.

Figure 8.1.1


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8.1.2 Clamp Cylinders and Levelling Roller Operation

Assuming Bag Presentation (Section 6.3.3) requirements, in Startup

and Operation Section have been met. The incoming bag operates theNo.2 photo-eye which initiates the Levelling Sequence as follows:

Leveller rollers clamp onto the bag separating the Infeed carrierbelts.

Leveller motors wind down the bag top until photo-eye beamstransmit across the top of the bag.

Bag stop arm retracts and the Leveller Rollers simultaneouslyunclamp enabling the Infeed carrier belts to grip the bag.

Together with the Sealer Conveyor, the Infeed carrier beltstransport the bag into the Cleaning Section carrier belt nip.

Figure 8.1.2


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Note: The clamp cylinders should operate at full speed thus ensuring repeatability.

Failure to do so can result in the in-coming bags to topple in one direction orthe other.See TROUBLE SHOOTING Section 14 for fault finding.

8.1.3 Levelling/Bar Too Low Photo Cell Care

For correct functioning of the leveller, ensure that the photo cells arekept clean. Powder build-up on their faces will reduce efficiency.

Note: Air jets are mounted below each photocell which blow clean dry air acrosstheir faces to reduce powder build up. These jets should always be directed atthe red light emitting from the photocell.

To clean the photocell properly, it is necessary to remove the 2 x M6cap screws and lift the plate and photocell assembly clear of the dustextraction chamber. It is advisable to mark the position (centreline ofthe photocell) on the front of the guide to which it is bolted. Oncecleaned, it can then be reinstalled at the same height.

Note: Care should be taken to ensure that the reinstalled photocell has a clear line ofvision through the hole in the front guide bar. If it is misaligned or oversensitive it may occasionally pick up the edge of this hole, and cause erraticoperation.

Partial cleaning of the photocell can sometimes be achieved withoutremoving it. This can be done with a warm damp cloth through the

holes in the guide bars. This is only an interim solution, and thoroughcleaning should take place once production pressures permit.

8.1.4 Bag Too Low/Bag Length Photo Cell

This photo cell, closest to the infeed, is positioned slightly lower thanthe low bag accept label and the levelling photo cells. It serves twopurposes:

1. To reject bags that have entered to low.

2. To auto track the bag width in conjunction with the encoder. This

allows the sealer to monitor width changes.


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This enables us to auto tune/adjust the following:

Bag central in leveller.

Cleaner entry and exit from bag time.

Reactivating flap auto raise and lower time.

Bag central at tuner.

8.2. Cleaner Section

8.2.1 Cleaner Operation

The purpose of the cleaner is to clean the seal area prior to heatsealing. Good quality seals can only be obtained if there is nocontamination in the seal area. refer to Diagram 8.2.1.

Clean unlubricated air is used for this purpose. This air supply isfiltered by the pure-air filter (Norgren 64 Series also used in the airheater on the Reactivation Station). Further details on the Air ServiceEquipment are in the Pneumatics Section 13.

The cleaner section also incorporates a dust collection duct whichwhen connected to the dust extraction mains, draws away any airborne dust blown from the seal area. The dust extraction is controlledby a pneumatically actuated butterfly valve which is only open whenthere is a bag in the cleaner section.

When a bag enters the cleaner section, the cleaning cycle isinitiated as follows: The bag opener cylinder retracts and pivotsthe vacuum cup onto the face of the bag.

Vacuum is applied to this cup via a pilot operated pneumaticvalve.

Once the vacuum cup has adhered to the bag, the bag openercylinder extends to pull away the front half of the bag from the

rear half, thus forming an envelope for the cleaner probe to swinginto.

The cleaner probe swings down into the bag.

The cleaner probe Air Jets blast away powder contamination fromthe liner seal area.

The cleaner probe swings up just in time to clear the trailing edgeof the bag.


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Figure 8.2.1


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9. Heat Sealing Page 1 of 8

9. HEAT SEALING

9.1. Seal Heating

9.1.1. The Heating Zones

Heat sealing takes place immediately after seal cleaning. There arethree individually controlled heating zones on the Model 41Amachines. These are Zones 1-3, each zone comprising of 2 front and 2rear heating dies.

Typical zone heat up time form ambient (12-18 degrees Celsius) to asetpoint of 225 degrees Celsius is 8-10 minutes.

9.1.2. The Temperature Controllers

Temperature control is carried out by four (3) solid state temperaturecontrollers housed in the control panel. These constantly monitor thetemperatures of each zone, showing the individual zonetemperatures. The temperature for heat sealing is set duringcommissioning. It should not be necessary to alter this unlessconditions such as machine speed or bag construction change.

When the machine is up to operational temperature, the temperaturesof the zones will stabilise. This can be seen from the digital displayson the temperature controllers. These are small L.E.D.s located abovethe top L.H. corner of the digital displays. These L.E.D.s will flickerON continuously during zone heat-up and then go to OFF when thatzone reaches its setpoint temperature. They will then flick from OFFto ON and to OFF as they pulse control power out to the Line Voltagecontrol cards housed in the Field Control Boxes to maintain setpointtemperature.

Full details on the temperature controller are contained later in thismanual. See the Appendix B.

Indicator lamps are on the control panel for each zone. These lampsilluminate during overheat or underheat conditions.

Note: As there is only one temperature probe (thermocouple) into one of the fourdies per zone, failure of 1 or more of the remaining 3 dies to heat up will not beshown on the temperature controller readout.


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9.1.3. The Field Control Boxes

Each zone has its own Field control on the back of the machine spine.

This houses wiring terminations, fuses and solid state relays forswitching Line Voltage on and off. Most importantly, there are fusefailure L.E.D. labels on the face of each box. These should be checkedwhenever a suspect seal check is recorded and at each start-up. AnON L.E.D. indicates fuse failure for that particular heating die. Inthis case an electrician should be called to investigate the cause of thefuse failure.

Figure 9.1.3 Fuse Failure L.E.D Label


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9.1.4. Heating Die Adjustments

Heating die adjustment is only required if there is a change in bag

construction or there are doubts about seal quality. The rear dies arefixed, so only the front spring loaded dies are adjustable.

The dies are factory set and again checked during commissioning. Fora standard 4 ply tubular multiwall bag, of 1.2mm (0.048 inch)thickness, the gap between the dies is 0.5mm (0.020 inch), giving apreload of (0.028 inch) 0.70mm.

To adjust the die gap, read the following in conjunction with Figure9.1.4 later in this section ( Letterers in brackets refer to this diagram).

1. Back off M5 tension screws (B) using an 8mm open endedspanner. To do this loosen the lock nut and back the screw offuntil it is flush with the inside of the stainless plate which it isscrewed through.

2. Loosen the main M6 mounting bolts (A) and slide the slottedmounting block forward until the front die is just touching thefixed rear die. As this block is tapered, it may be necessary toloosen the M6 bolts quite a long way before the block can slidefully forward.

3. Retighten the M6 (A) bolts when the block is fully forward, and

just touching the fixed rear die.4. Using the 8mm open ended spanner to adjust the M5 (B) screws,

and a feeler gauge or similar to measure the gap, wind in the M5(B) screws until the gap opens up to an even amount at each end.

5. The feeler gauge or gap setting should be 0.7 or 0.5mm (0.028 to0.030 inch) thinner than the thickest part of the in bag in use. It isusually necessary to first measure the bag thickness usingverniers or a micrometer and then determine the gapaccordingly.


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Figure 9.1.4 Die Gap Adjustment


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9.2. Seal Compression

9.2.1. DescriptionThe purpose of seal compression is to consolidate the plastic sealsurfaces together to form an effective airtight and asceticallyacceptable seal. This is accomplished immediately after the HeatSealing Section, approximately central on the Sealer. The Carrier beltterminates at this point as the drive is transferred from the DriveCarrier belt via a Simplex Chain Drive.

Note: Too much pressure from the compression wheels will thin the molten plastic inthe seal section and leave a weakened and ineffective seal. Too little pressurewill result in an ascetically unacceptable or barely adequate seal.

The correct compression pressure will result in a seal that will have aneven opaque appearance.

Too much compression pressure can be observed as holes through theseal wherever the highest pressure points are, e.g. coinciding withKraft seams.

Too little pressure can be observed as a mottled pattern of clear andopaque patches along the seal section.

Note: Although seal compression is an integral aspect of seal quality, it must not beforgotten that the biggest contributor to seal qualify is sealing temperaturewhich can be effected by machine speed and cleaner efficiency.

9.2.2. Operator Adjustment

Although both the rear and front Seal Compression wheels areadjustable, adjustment of the rear Seal Compression wheel should notbe necessary as it is preset during assembly, so as the outsidediameter is along the centre line of the bag path. Access to theadjustments on the rear Seal Compression wheel is restricted, and anyattempt at adjustment should be avoided, unless a major change inbag construction dictates this action. Seal Compression adjustment isvia the FRONT Seal Compression wheel. Adjusting bolts are readilyaccessible. See Section 9.4 (Letters in brackets relate to letters in Figure9.4).


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9.3. Seal Scoring

9.3.1. DescriptionThe purpose of the scoring wheel is to score (Cut by compression)through the sealed part of the inner plastic liner, along its top edgeand up to 1mm (0.040 inch) down from this edge, while the seal is in asoft, pliable state. Separation of the filled liner from the portiontrapped by the reactivated bag closure effectively frees the pouchwithin its multiwall outer. The bags outer Kraft is structurallyunaltered and remains intact. The Scoring Wheels simply applypressure to the pliable plastic which causes point of contactthinning leaving a very tenuous connection, if not total separation ofthe pouch.

Although both the rear and front Scoring Wheels are adjustable,adjustment of the rear Scoring Wheel should not be necessary as it ispreset during assembly so as the outside diameter is along the centreline of the bag (carrier belts). Access to the adjustment on the rearscoring wheel is restricted and any attempt at adjustment should notbe avoided, unless a major change in bag construction dictates thisaction. Scoring pressure adjustment is via the front scoring wheel.


Scoring Wheel adjustment is carried out in exactly the same way asthe Compression roller adjustment i.e. via the FRONT of the machine.See Section 9.4 (Letters in brackets relate to letters in Figure 9.4).

Note: Scoring wheel gap is critical for good seal quality and long life of components.For standard 4 ply tubular bag, the recommended gap is 0.020 inch to 0.024inch (0.5mm to 0.6mm). This can vary with bags of differing constructionwhether this be the number of plys or P.E. liner type.


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9.4. Seal Compression/Scoring Wheel Adjustment

-Use a FEELER GAUGE or SHIM to set the gap.

Figure 9.2.2 Seal Compression/Scoring Wheels

To Adjust:

1. Loosen the 4 x M8 cap screws which clamp the assembly (1).

It may be necessary to also loosen the two adjacent M8 cap screws(1) which clamp the Scoring Wheel.

Both PUSH (close gap) (3) adjusters AND PULL (open gap) (2)

adjusters are provided. The push adjusters are 2 x M6 grub screws(3) and pull adjuster is a single M6 cap screw (2). Feeler gaugers orshims should be used to set the gap.


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2. To CLOSE the gap, loosen the M6 cap screw (2) and push thescoring wheel inwards using the 2 x M6 grub screws (3), windingboth screws an even amount. Once the gap is correct, nip up the

M6 cap screws to pull the assembly tight (2).3. To OPEN the gap, loosen the 2 x M6 grub screws (3) and pull back

the assembly by screwing in the M6 cap screw (2). Once the gap iscorrect, nip up the 2 x M6 grub screws to hold assembly tight (3).

4. Once the adjustment is correct, tighten the 4 x M8 clamping capscrews (1).

Note: Compression wheel gap is critical for good seal quality and long life offcomponents. For standard 4 ply tubular bag, the recommended gap is 0.030 to

0.040 (0.75mm to 1.0mm). This will vary with bag type, manufacture andconstruction.

9.5. Seal Cooling

9.5.1. Description

The purpose of the cooling section is to start to cool down the sealarea of the bag so that downline handling does not rupture a stillplastic seal i.e. the cooling process is the seal curing process.

The cooling section of the 41A Sealer Closer comprises of one pair ofdies. They are located immediately after the scoring/seal compressionrollers. These dies have the same profile as the heating dies and arealso mounted in the same way.


As the mounting is identical to that of the heating dies, the method ofadjustment is the same, refer Section 9.1.4.


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10. Bag Top Closer Section Page 1 of 7

10. BAG TOP CLOSER SECTION

10.1 Bag Top Closer

10.1.1. Bag Top Closer Assembly

The Bag Top Closer Assembly closes the stepped outer flap andreactivates the hot melt glue to close the outer multiwall bag. This isthe CLOSURE. It is comprises of 5 main components as follows:Refer Figure 10.1

1. The BAG TOP CLOSER FLAP which takes the top 41-43mm(and for some bags up to 50mm) (1 5/8 1 inch) of the bag andfolds it through 180 degrees to adhere it back against the vertical

face of the bag. This guide folds the bag top in two stages, the firstbeing the primary fold and the second being the final fold toadhere it to the bag face.

2. The FRONT FOLD GUIDE over which the top portion of thebag is folded. This supports the front of the bag during folding.

3. The REAR FOLD GUIDE supports the back of the bag duringfolding.

4. AIR HEATER PLENUM CHAMBER, which contains numeroussmall holes, on its upper surface, through which the hot airpasses, to reactivate (melt) the pre-applied adhesive.

5.

The AIR HEATER. Clean dry air passes over the encapsulatedheating element to be heated before entering the air heaterplenum chamber.

10.1.2. Operator Adjustments

Should the factory fold guide adjustment be disturbed, due to dis-assembly for cleaning or similar, it is necessary to reset them asfollows: refer Figure 10.1.

1. The Bag Top Closer flap is first raised via the Operators ControlPanel.

2. Part the final drive carrier belts with an engineers steel rule (orsimilar) and position alternative at the infeed and exit (parallel)ends of the Rear Fold Guide (R.F.G.).

Note: Care must be taken when parting the carrier belts as no responsibility isassumed by Sapac Developments for carrier belt damage.


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If the R.F.G. does not line up with and touch, the inserted rule atboth infeed and exit ends; (i.e. the R.F.G. is not parallel to andabove the centre line of the bag path) then adjustment may benecessary.

3. To adjust the R.F.G., loosen the Four (4) M6 hold-down bolts atthe rear of the guide and tap forward to comply with 2 above.When alignment is satisfactory tighten down the M6 bolts.

4. The front fold guide (F.F.G.) is set off the R.F.G. (when in correctposition as described in 2 above).

To set the F.F.G. loosen the four (4) M6 hold down bolts along thefront of the F.F.G.

CAUTION: If the Bag top Closer assembly is hot, particular careis advised when loosening the two (2) M6 bolts located under theAir Heater / Plenum Chamber.

Gap set the F.F.G. 3mm (1/8 inch) away from the R.F.G. for astandard 3 or 4 ply bag of flat tube construction.

Re-tighten the four (4) M6 bolts when adjustment is satisfactory.

Note: Should bag construction be other than that above, the rule of thumb for gapsetting is as follows:

Bag thickness measured at thickest point by micrometer or vernier x 2 1/4 =gap setting (initial).

5. With the Closer Flap still raised, manually feed an empty bag intothe machine and observe its passage through the fold guides.

When the gap set is satisfactory the Bag Top Closer adjustmentcan be carried out as follows: with the B.T.C.F. still in the upposition manually feed into the machine an empty bag and stopthe said bag when it is positioned about centrally in the closerassembly. To stop the machine, operate the Drive/ConvSTART/STOP button on the operators control panel.

Note:Should the test bag (5 above) hesitate or snag at any point during its passage,through the fold guides the gap set at the point of snagging should beincreased to avoid same.

6. By hand, fold the bag top over the F.F.G. so it is lying horizontallyabove the plenum chamber.

7. Via the Bag Top Closer Flap UP/DOWN switch (operators control

panel) lower the B.T.C.F. and check that it does not pinch the bagtop fold directly on top of the F.F.G.


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8. If adjustment of the B.T.C.F. down position is required this mustbe carried out at the piston rod end of the flap actuator.


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Note:While there must obviously be enough clearance between the B.T.C.F. and the

top of the F.F.G. it is desirable that this clearance be the minimum amountrequired to allow free passage of the bag since this adjustment is arguably themost critical for producing a parallel fold.

9. The final closure fold is also a function of the B.T.C.F. adjustment.This final fold adjustment is carried out at the B.T.C.F. hinge onthe outfeed end of the said flap. So that the final fold follows theoriginal first fold crease, the gap between the diagonallypositioned B.T.C.F. rod (see Figure 10.1) and the F.F.G. must beset to about 1 the micrometer or vernier measured bag thickness.

10.

To carry out the adjustment as in 9 above, with the B.T.C.F. downloosen the M6 bolt which attaches the B.T.C.F. to its hinge bar andmove the flap in or out depending on whether a smaller or greatergap is required.

Figure 10.1 -Bag Top Closer Assembly


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10.1.3. Air Pressure Requirements

For normal operation initial air pressure setting can be 20 psi. Somevariation may be warranted for unusual conditions but generally thiscan be considered a fixed condition of operation.

Dusty products that tend to coat the adhesive applied to the bagmight require the air pressure to be increased by 1 or 2 psi. Productcontamination of the adhesive area should be avoided where possible.

A pressure regulator and gauge are each panel mounted in the frontface of the machine spine above the re-activation station. The closerair pressure sensing switch is accessible by removal of the rearinspection panel immediately behind the pressure regulator and

gauge.

Note:The pressure switch is set to raise the CLOSER AIR alarm if the pressure isbelow 15 psi (trip pressure). The air heater will not switch on below this trippressure. This reduces the possibility of element burn out due to insufficientair flow.

The pressure regulator is a low pressure type, and has a maximumpressure output of 25 to 30 psi. This maximum pressure can thereforenot be exceeded.

Layout details of the pneumatics concerned with this station arecontained later in this section.

10.2. Bag Top Compression

10.2.1. Description

The purpose of bag top compression is to secure the adhesive bondbetween the folded over stepped end of the bag and its out ply.

After exiting the Bag Top Closer, the folded bag top is gripped

between the two compression belts and pressed between them justprior to exiting the machine. Refer to Figure 10.2 for diagram.

The compression belts are toothed timing belts which are non-marking. They are driven directly by the geared drive via timingpulleys.


As the compression belts are inherently low stretch design, thedistance between the driving and idling timing pulleys does not need

to have adjustment for tensioning.


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The front compression Idle Rollers are sprung loaded against thecompression belt and no adjustment has been found to be necessary.


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10.2.3. Compression Belt Cleaning

While the belts themselves could be expected to stay clean when allconditions are perfect; when temperatures are too high, air flow is toogreat or there is a variation to reactivation adhesive during bagmanufacture, some build up may be experienced on the CompressionBelts.

Adjustable scrapers are fitted to the centre outer side of the belt (oneeach side) to keep this build up to a minimum.

These are set just clear of the belts to remove excess adhesive buildup, but can be adjusted closer if, during production, it is feltnecessary.

ADJUSTMENT is done by loosening the M8 cap screw and pivotingthe edge of the scraper in towards the belt face. Always retighten thiscap screw after adjustment.

CAUTION: DO NOT ADJUST THE SCRAPER TOO CLOSE TOTHE BELT OR DAMAGE MAY RESULT,REDUCING BELT LIFE OR DAMAGING THEDRIVE.

Figure 10.2 -Bag Top Compression Assembly


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11. Conveyor Page 1 of 2

11. CONVEYOR

11.1. IntroductionThe Sealer Conveyor is a standard Sapac build unit and its primary function isto accept bags from the Packing Machine and feed them through the NeckStretcher and Sealer Closer.

The Conveyor speed is fixed and thus the Sealer speed requires synchronisingwith same. See Section 6.3.2 for a description of this process.

The Conveyor head, tail and tension rollers are of an open cage design,running in flange bearings. The belt is standard width and is driven as perspecifications below. For belt tensioning and tracking instruction refer to themaintenance section (Section 14.13) .

11.2. Conveyor Specifications

Serial #` C164

Side Length (mm) 5000 Overall

Belt Length -N.F.L. (mm) 10800 (425)

Belt Width (mm) 300 (12 inch)

Belt Type LEDER 2/U2/UO/6

Belt Construction Endless Spliced to N.F.L.

Drive SEW SA57TDT80N4 Geared ElectronicMotor 0.75kW/19.2 rpm

Theoretical Belt Speed (m/min) 6.3


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11. Conveyor Page 2 of 2

Figure 11 Conveyor


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12. Electrical Page 1 of 2

12. ELECTRICAL

Temperature Control Settings 0C

Level Parameter Zone 1 4 Setting Zone 5 Setting

1 TUNE OFF OFF

1 BAND 21 14

1 INT.T 2.5 2.7

1 DER.T 11 13

1 DAC 1.5 1.5

1 CYC.Tt 10 11

1 OFST 0 0

1 SP.LY OFF OFF

1 SET.2 10 10

1 BND.2 2 2

1 CYC.2 ON/OFF ON/OFF

2 SPL.P 100 100

2 HAND OFF OFF

2 PL.1 100 100

2 PL.2 100 100

2 SP2.A BAND BAND2 SP2.B NLIN NLIN

2 DI.SP 10 10

2 HI.SC 300 300

2 LO.SC 0 0

2 INPT TCJ TCJ

2 UNIT 0C 0C

2

3 SP1.D SSD SSD

3 SP2.D RLY RLY

3 BURN 1D2U 1D2U

3 REV.D 1R2R 1R2R

3 REU.L 1N2N 1N2N

3 SPAN 0 0

3 2 ERO 0 0

3 CHEK OFF OFF

3 REA VAR0 VAR0

3 DATA CTA CTA

3 VER 2 2

3 RST NONE NONE


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12. Electrical Page 2 of 2

Temperature Control Settings 0F

Level Parameter Zone 1 4 Setting Zone 5 Setting

1 TUNE OFF OFF

1 BAND 21 14

1 INT.T 2.5 2.7

1 DER.T 11 1.3

1 DAC 1.5 1.5

1 CYC.Tt 10 11

1 OFST 0 0

1 SP.LY OFF OFF

1 SET.2 10 101 BND.2 2 2

1 CYC.2 ON/OFF ON/OFF

2 SPL.P 100 100

2 HAND OFF OFF

2 PL.1 100 100

2 PL.2 100 100

2 SP2.A BAND BAND

2 SP2.B NLIN NLIN

2 DI.SP 10 10

2 HI.SC 5720F 5720F

2 LO.SC 320G 320F

2 INPT TCJ TCJ

2 UNIT 0F 0F

3 SP1.D SSD SSD

3 SP2.D RLY RLY

3 BURN 1D2U 1D2U

3 REV.D 1R2R 1R2R

3 REU.L 1N2N 1N2N

3 SPAN 0 0

3 2 ERO 0 0

3 CHEK OFF OFF

3 READ VAR0 VAR0

3 DATA CTA CTA

3 VER 2 2

3 RSET NONE NONE


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13. Pneumatics Page 1 of 9

13. PNEUMATICS

13.1. Pneumatic Lubrication (For machines with airline lubrication)

As the manufacturers of the Sapac Sealer Closer, Sapac, together with ourpneumatic equipment suppliers feel that we should point out the benefits ofproper lubrication of the pneumatic prime movers, ie. the pneumaticactuators.

With proper lubrication the above mentioned actuator seals can travel at least3000km without attention.

Quote ex Applied Pneumatics International Journal, Volume 11, November1987, page 12.

"At regular intervals we take a cylinder at random from the production lineand test the seals to destruction. During the course of these tests, the pistonwill travel the equivalent of from our factory to Barcelona and back, whichmeans in service you can expect our cylinders to travel at least 3000kmwithout attention".

Further we quote from the British Compressed Air Society Code of Practice:"The importance of correct lubrication of pneumatic equipment cannot be overstressed. It decreases friction, reduces wear and prevents corrosion of themoving parts. The most efficient and economical method to lubricatepneumatic equipment is to introduce the oil in droplet form into the airstream. As a general rule use 1 drop of oil (0.02 millilitre approximately) toeach 280 dm3 (10 cu ft) of air consumed".

Note: To put the above into context it is important to qualify it by identifyinginformation as being pertinent to the Oil-Fog type Lubricators only. All Sapacequipment uses Micro-Fog Lubricators. Guidelines for their operationaladjustment follows.

The Micro-Fog lubricator passes into its airflow only a small percentage of theoil seen dripping through the sight dome. Because only the finer particles arepicked up by this air flow, a drip rate of 10 to 20 times higher than the oil-fog

unit described above, will be set when adjusting the Micro-Fog design.

Note: This gives a recommended minimum drip rate of 10 drops (0.20 millilitreapproximately) to each 280 dm3 (10 cu ft) of air consumed. Actual applicationmay vary from this amount but it is a good starting point. Recommendeddrop rate is 1 drop per 7 machine cycles.

It can therefore be readily seen that lubrication rates need to be referenced toair consumption figures.


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Standard pneumatic lubricating oil (mineral oil, Castrol AWS 32), may be usedin all these lubricators.

Medical paraffin instead of lubricating oil may be used throughout alllubricators if so desired.

LUBRICATORS MUST BE CHECKED DAILY FOR CORRECTADJUSTMENT AND KEPT FULL OR PREMATURE PNEUMATICCYLINDER AND COMPONENT WEAR COULD RESULT.

The Micro-Fog type lubricators are easily identified by a visual check at the

adjusting knob situated just above the sight dome. The adjusting knob will befitted with a red locking ring.

In addition to the above and regardless of the colour of the locking ring, theMicro-Fog unit, when in operation can be identified by the ever present cloudof oil vapour sitting above the liquid oil in the lubricator bowl.

Note: If you have a Micro-Fog Lubricator which is not producing a visible vapourcloud above the liquid oil when the machine is cycling, you must take stepsto remedy the situation without delay so as to minimise pneumaticcomponent wear.

Figure 9.1 Norgren Lubricator


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13.2. Pneumatic Schematic

For Pneumatic Schematic Drawings see Appendix A

13.3. Pneumatic Components

.1. Actuators

LEVELLER SECTION

Item Description Qty Actuator Type

AA Bag Clamp Cylinder 2CHANTO D/A PneumaticCylinder CM38BX 25SP

AB Bag Stop Arm Actuator 1 Kuroda D/A ActuatorPRN-300-90-40

CLEANER SECTION


CB1 Bag Opening Cylinder 1 Norgren D/A CylinderM/6025/05

CB2 Dust Extraction Cylinder 1Norgren D/A CylinderM/6025/75 L

DB Cleaner Probe RotaryActuator

1Norgren Rotary ActuatorM/60283/90

CLOSER SECTION


CB3 Closer Flap Cylinder 1 Norgren D/A CylinderM/6025/50 FL


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.2. Control Valves

CONTROL VALVES (Standard Machine)


B1 45A-LCC-DACJ-2KD4/2 Mac SingleSolenoid Valve

2 Leveller Section

5 Cleaner Section

B2 45A-LCD-DACJ-2KD4/2 Mac Solenoid Valve withflow controls

1 Closer Section(at rear)

B3 712C-14-PE-B12JD4/2 MAC Single Solenoid Valve

1 Leveller Section(at rear)

B4 55B-24-RE 3/2 Mac PilotOperated Valve

1 Cleaner Section

B5 55B-14-RA 3/2 MACPilot Operated Valve

1 Leveller Section

CONTROL VALVES (D.I.P. Machine)


B1 45A-LCC-DACJ-2KD4/2 Mac SingleSolenoid Valve

2 Leveller Section

6 Cleaner Section

(see figure 13.3.5)

B2 45A-LCD-DACJ-2KD4/2 Mac Solenoid Valve withflow controls

1 Closer Section(at rear)

B3 712C-14-RA4/2 MAC Single Solenoid Valve

1 Leveller Section(at rear)

B4 55B-24-RE 3/2 Mac PilotOperated Valve

1 Cleaner Section

B5 55B-14-RA 3/2 MACPilot Operated Valve

1 Leveller Section


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.3. Pneumatic Equipment

EQUIPMENT


A1 T13-400-E2ADNorgren 3/2 Shut off Tap

1 Machine Spine(Rear Centre)

A2 B64-GNN-KMD3Norgren Filter/Regulator

1 Cleaner Section

A3 LO7-200-MPQDNorgren Mico-Fog Lubricator

1 Cleaner Section

A4 F64-CNN-DMDONorgren Pure-air Filter

1 Cleaner Section(Supply to allpneumatic valves)

A5 RO7-100-RNEGNorgren Pressure Reg 0-3.5 bar

1 Closer Section

A6 18-013-996Norgren Pressure Reg

1 Closer Section

A7 LPS 10/2Compare Pressure Switch

1 Closer Section

A8 ZSM-1-121LS.M.S. Pressure Switch

1 Closer Section

Figure 13.3.1 Main Frame Pneumatic Location


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Figure 13.3.2 Leveller Section Pneumatic Location


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Figure 13.3.3 Cleaner Section Pneumatic Location


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Figure 13.3.4 Closer Flap Pneumatic Location


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Figure 13.3.5-Cleaner Section Valve Stack (Standard Mc)

Valve No. Valve Type Valve Duty

1 45A-LCC Vacuum ON/OFF Pilot Valve

2 45A-LCC Dust Extraction CylinderDirectional Valve

3 45A-LCC Bag Opener Cylinder Valve

4 45A-LCC Cleaner Probe Actuator DirectionalValve

5 45A-LCC Bag Clamp Cylinder DirectionalValve


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14. Troubleshooting & Maintenance Page 1 of 29

14. TROUBLESHOOTING &MAINTENANCE

14.1. Levelling Mechanism

14.1.1. Troubleshooting

The levelling mechanism, as with all other mechanisms on the SapacSealer Closer should operate relatively trouble free.

There are however some problems which can re-occur especially ifthe dust extraction at the leveller section is inadequate or if thepacking machine is not fitted with a genuine Sapac Bag Clamp.

Warning:

Read Safety Section 5 before any maintenance or adjustments arecarried out

Stop machine and disconnect power supply before servicing orrepairing. Maintenance and adjustments must be performed withall power supply disconnected unless otherwise specified in thismanual.

High-pressure air systems are dangerous. Do not service ortrouble-shoot systems with air supply on. Be sure to bleed off anytrapped air before working on components since it is possible tohave high pressure trapped in airlines.

FAULT: THE BAG POPS BACK UP AT ONE END OR THE OTHER AFTERLEVELLING

Cause Solution

Carrier Belt Guide Slide iscontaminated with Powderproduct.

Check for powder contamination.

Springs have weakened through

high cycle fatigue.

Check by hand that the front belt guide is free to move

back against its return springs and that they haveenough compression to return the guide to its driveposition i.e. hard against the compression belts.

Check the uncompressed spring length.Uncompressed spring length should be 80mm or more.


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FAULT: FOLDS

Bag Fold Tapered/Uneven

Levelling height photocells atdifferent heights

Over-Levelling

Levelling height photocells to low

Under-Levelling

Levelling height photocells to high

Good Fold


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14.2. Levelling Mechanism

14.2.1. MaintenanceFor correct functioning of the leveller, ensure that the photo cells arekept clean. Powder build-up on their faces will reduce efficiency.Operator care of the photo cells is outlined on Section 8.1.3.

The sensitivity of the photo cell should not need adjusting. Ifadjustment appears necessary, first check that the photo cell face isclean. If it is found that adjustment is required, this is carried out onthe amplifier to which the photocell is connected, via its fibre opticcable. The amplifiers are located nearest to the infeed end of themachine, next to the valve stack. A slotted sensitivity adjustment is on

the face of each amplifier. Details on amplifier type and setting arecovered in the Appendix.

Basically the sensitivity should be such that every bag entering themachine and passing the face of the photocells must be detected. Thephotocells are each mounted on a small stainless steel plate with 2 xM6 cap screws. The plate is slotted to allow for height adjustment toensure bags are levelled to the correct height. Once the height isdetermined it should not need altering.

Figure 14.2 Photo Cell Diagram


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14.3. Cleaner Mechanism

14.3.1. TroubleshootingBecause of its nature (vacuum cup adhesion) the Cleaner SectionOperation is undoubtedly the most temperamental aspect of theSapac Sealer Closer. There are several reasons why the opening andcleaning of the bag seal area should be difficult.

Stepped pattern of the bag top often leads to unavoidableundulations in the area of vacuum cup contract.

Limited adhesion force of the vacuum cup i.e. negative 1atmosphere x vacuum cup contact area (small due to physicalrestrictions).

From necessity a sensitive, lightly constructed, vacuum cupguidance system (slide).

However, there is no reason that we are so far aware of, why aproperly adjusted and maintained Bag Cleaning Mechanism cannotwork as reliably as the rest of the machine provided that bagconstruction falls within our recommended Users Bag.

FAULT: VACUUM CUP FAILS TO ADHERE TO OR FOLLOW BAG ie CLEANERPROBE UNABLE TO ENTER BAG TOP

Cause SolutionVacuum cup damage due towear or improper installation

Replace damaged vacuum cup.

Ascertain reason for cup damage in order to preventfuture damage.

Vacuum cup slide movementencumbered.

Check for build up of product on the shafts causingsticking.

Check that the silicone vacuum supply tube is notrestricted in its movement.

Check that the vacuum cup holder return spring is atits rest position

Low Vacuum. Check that the vacuum generator is functioningcorrectly

Check that vacuum valve is functioning correctly.

Check that the vacuum on output is present at thevacuum valve pilot solenoid.

Bag opening cylinder ismalfunctioning

Check for seal failure or physical damage.

Check for tightness at cylinder pivot points. Check for tightness in main pivoting block bushes

to which sliding shafts are mounted.


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Check that the vacuum switch is adjustedproperly.

Note: Care should be taken when fitting new vacuum cup slide springs not to

stretch the springs as this would increase their compressive strengthmaking it difficult for the cup slide to operate correctly. Doing this willcause the cup to break free when the bag is pulling it along whileopening the bag top. This will cause cleaner errors. Only light springtension is required when the shafts are clean and everything else isworking, as it should.

Figure 14.3 Cleaner Mechanism


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14.4. Heating Dies

14.4.1. TroubleshootingHeating Die malfunction is a possibility from both mechanical andelectrical points of view. Mechanically, seals may be affected throughmisalignment of the front heating dies while electrically, seals may beaffected from an over or under heat condition of the die itself.

FAULT: HEAT SEALS ARE NOT UNIFORM IN WIDTH OR OF INIFORM TEXTURE,ARE INCOMPLETE OR CLEAR

Cause Solution

Two or more Heating Dies arefailing to reach set point temp.

A quick check of the Fuse Failure L.E.D. labels on theField Zone Control boxes mounted on the rear of themachine spine will indicate whether failure of two ormore dies is from a blown fuse (see The Field ControlBoxes Section 9.1.3). Other electrical causes for HeatingDie failure could be an open circuit cartridge elementor lead. To check out get an electrician to do a voltagecheck across the cartridge element terminations ie.When the Temperature Controller Output L.E.D. is

ON (see Section 9.1.2) there should be 220 Volts (moreor less) across each cartridge element.

The front dies are not sittingparallel to the rear dies in thevertical plan ie. Top edge of theheating die profile is exertingmore pressure then the bottomedge.

If no evidence of electrical failure is present it could bepossible that die pressure adjustment has been carriedout wrongly ie. Too much pre-tension on the frontHeating Die springs will tend to roll the Die Profiledownwards out of parallel with the back Die profile.

Note:One probable cause of rolling is that when initially pushing the die facestogether, there has been too much pressure applied. It is important that thefaces only just touch. See Section 9.1.4 for Heating Die Adjustment.


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FAULT: BAG OUTER PLY IS BEING SCORCHED ie BROWN TRACKS WHERE THE

BAG HAS BEEN IN CONTACT WITH THE HEATING DIE PROFILECause Solution

The above can only be causedby overheated dies. Assumingthat the machine is running atrecommended die temperatures.(See temperature controllers onoperators control panel) thisproblem can be caused by oneof the Heating Cartridge

Element leads going to ground.

If the Temperature Controller digital displays all checkout O.K. See Section 7.2 switch OFF the Sealer HeatON/OFF switch, on the operators control panel, andhave an electrician check out the Field Boxes (seeSection 9.1.3).

Note:The thermocouple carrying the Heating Die will always indicate a fault specificto itself on the Operators Control Panel i.e. Alarm Indicator Lamp ON for overor under under heat or Temperature Controller digital display ofthermocouple fault conditions.

14.5. Seal Compression Wheels


FAULT: THINNED WEAKENED SEAL

Cause Solution

Too much pressure at the SealCompression wheel.

For operator adjustments see Section 9.2.

FAULT: SELA OBSERVED AS MOTTLED PATTERN OF CLEAR AND OPAQUEPATCHES ALONG THE SEAL LINE.

Cause Solution

Provided that Heating Dies areall operating, then the causewould be lack of pressureexerted from the SealCompression wheels.



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14.5.2. Maintenance

Maintenance of the Compression Wheels is not generally required,

however if after the correct gap procedure is carried out and it isfound that seal compression is not being achieved (See Section 10) wewould advise a visual inspection of the Compression O Rings (D) isrequired (See Figure 14.5).

To inspection the O ring (D) remove M6 bolts (A) and lift retainingring (B) and moving ring (C) to expose same. Should replacementappear to be necessary the Heartbeat sensor/chain tensionerbracket, and rear drive transfer chain, must be removed (See Figure14.7).

Figure 14.5 Seal Compression wheel diagram


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14.6. Seal Scoring Wheels


FAULT: SEAL NOT BEING SCORED PROPERLY

Cause Solution

Improper adjustment of scoringpressure


Heat seal not of high enoughstandard to accomplish thescoring operation.

Refer to Heating Dies Troubleshooting Section 14.4.

14.6.2. Maintenance

As for Seal Compression Wheels maintenance section 14.5.2.

Figure 14.6 Seal Scoring Wheel Diagram


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14.7. Seal Compression/Scoring Wheels Drive Chain

14.7.1. MaintenanceVisual inspection from time to time of the drive transfer chain isadvised.

Note:The chain drive transfer of the Compression/Scoring Wheels can be re-occurring maintenance concern if the chains are left to run un-lubricatedthroughout the season.

Figure 14.7 Drive Transfer Chain Diagram


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14.8. Bag Top Closer


FAULT: LEAD EDGE OF FOLD FOLDED BACK

Cause Solution

Fold guides too tight For operator adjustments see Section 10.

Excessive adhesive build-up. Clean fold guides of adhesive build up.

FAULT: UNEVEN FOLD WITH BOWED BAG TOP

Cause Solution

Fold guides too loose For operator adjustments see Section 10.


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FAULT: CLOSER AIR PRESSURE IS ADJUSTED TO RECOMMENDED LEVEL

(AROUND 20 PSI) BUT ADHESIVE ON BAG CLOSURE FAILS TO ADHERETO THE OUTSIDE OF THE BAG

Cause Solution

Excessive powdercontamination of the adhesiveor bag outer in the closure area.

Check bag for excessive powder contamination

Failure of the Air HeaterElement to heat its transient air.

Check Temperature Controller set-point, see Sapacdefault settings Section 12

Check that the Temperature Controller is functioning

ie. digital display is not indicating a thermocouplefailure and that the output L.E.D. at the top left handcorner of the display is flickering.

Check for a blow line fuse at the Field Control Box (seeSection 9.1.3) mounted on the rear side of the Sealerspine at the Bag Top Closer Location (Zone 5).

Check the Air Heater element for open circuitcondition by opening the Field Control Box and doinga voltage check across the element leads. Voltageacross the leads should be 415 volts A.C. (more or less).

14.9. Air Heating Element

The air heating element is housed in a stainless steel tube (body).

14.9.1. To remove the element

Warning:

Ensure power is off before any attempt is made to remove the Air

heating Element Work must be carried out only by a qualified electrician.

Remove rear cover behind control

Remove element wires from terminals on solid state relay FieldControl Box.

Release both gland nuts from each end of spring conduit on entryto cable glands (A) cut cable ties (if used).

Remove element retaining M6 cap screw, which is threaded into

the end fitting (B).

Draw element from heater body by pulling back on end fitting(C).


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Remove conduit and gland nuts from element wire.


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14.9.2. To replace the element

Thread conduit and gland nuts back over new element wire.

Follow steps for removal (Section 14.9.1) in reverse order.

Figure 14.9 Air Heating Element


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14.10. Drive Train


FAULT: THE AUDIO BUZZER IS ALTERNATING ON AND OFF. TH

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Sealer Closer-Instruction manual