VPK Operations Manual

VPK Operations Manual

About this ManualThis manual is a reference tool for the Rovema VPK series bagmakers: modelsVPK-260 and VPK-360. It should be used in conjunction with instructor lead training.

The following information is include in this manual:

n Introduction

n Safety Instructions

n Parts and Functions

n Theory of Operations

n Operator Controls

n Machine Setup Procedures

n Operation Procedures

n Working with Components

n Changeover Procedures

n Maintenance Procedures

n Troubleshooting Procedures

n Appendix (Setup of Auxiliary Equipment)

How to Use this ManualThere are several ways to find information in this manual:

n The Table of Contents lists the chapters and sections of the manual

and their corresponding page numbers.

n The header at the top of every page indicates the name of the chapter.

n The bottom of every page contains the page number, the manual

number, and the revision date.

Table of Contents

Rovema VPK Operator�s Manual

3/2000 VPK REV(B) PANELVIEW 600 I

Table of Contents

Introduction ..................................................................................................... 1-1

Safety Instructions .......................................................................................... 2-1Safety Devices ....................................................................................................... 2-2

Guard Doors............................................................................................................... 2-2EMERGENCY STOP Push-Button ............................................................................ 2-3Safety Labels.............................................................................................................. 2-4

Component Safety ................................................................................................. 2-5Operator Safety ...................................................................................................... 2-6

Operator Safety Guidelines ...................................................................................... 2-6

Lockout Procedures .............................................................................................. 2-7Air Supply Lockout .................................................................................................... 2-7Power Lockout Procedure ........................................................................................ 2-8

Parts and Functions ........................................................................................ 3-1Film Carriage .......................................................................................................... 3-2

Film Spindle ................................................................................................................ 3-3Dancer Assembly ....................................................................................................... 3-4Film Unwind Brake ..................................................................................................... 3-5Film Tracking Assembly............................................................................................. 3-6

Touchscreen Controls .......................................................................................................... 3-7

Out of Film Sensor Assembly ................................................................................... 3-8Guide Rollers.............................................................................................................. 3-9

Film Feeding Device ............................................................................................ 3-10Belts Assemblies .......................................................................................................3-11Drive System ............................................................................................................ 3-12Engage/Retract Device ............................................................................................ 3-13

Touchscreen Controls ........................................................................................................ 3-14

Forming Set.......................................................................................................... 3-15

Table of Contents


3/2000 VPK REV(B) PANELVIEW 600 II

Table of Contents (continued)

Vertical Sealing Device ........................................................................................ 3-16Seal Band Unit .......................................................................................................... 3-17

Heating Bar ........................................................................................................................ 3-18Sealing Band, Band Sensor, and Band Release Lever ...................................................... 3-19Drive System ..................................................................................................................... 3-20

Engage/Retract Device ............................................................................................ 3-21Touchscreen Controls ........................................................................................................ 3-22

Seal Band Support ................................................................................................... 3-23

Horizontal Sealing Device ................................................................................... 3-24Jaw Assemblies ........................................................................................................ 3-25

Jaw Body ........................................................................................................................... 3-26C-Frames, Jaw Carriers and Jaw Springs .......................................................................... 3-27

Seal Pressure ........................................................................................................... 3-28Drive System ............................................................................................................ 3-29


Knife Assembly ........................................................................................................ 3-31Touchscreen Controls ........................................................................................................ 3-32

Temperature Controllers ......................................................................................... 3-33

Registration Sensor ............................................................................................. 3-34Touchscreen Controls ............................................................................................. 3-35

Pneumatics System ............................................................................................. 3-36Primary Manifold ...................................................................................................... 3-37Pressure Switch ....................................................................................................... 3-38Horizontal and Vertical Cooling Devices ................................................................ 3-39Vacuum System ....................................................................................................... 3-40Solenoid Bank .......................................................................................................... 3-41

Optional Equipment ............................................................................................. 3-42Bevel Plates .............................................................................................................. 3-43Bag Grippers ............................................................................................................ 3-43Foam Deflators ......................................................................................................... 3-43Splice Table .............................................................................................................. 3-44Automatic Film Tracking Sensors........................................................................... 3-45


Table of Contents


3/2000 VPK REV(B) PANELVIEW 600 III


Bag Shaping Devices............................................................................................... 3-47Gusset Device ................................................................................................................... 3-48

Touchscreen Controls .................................................................................................. 3-49STABILO SEAL® Sealing System ...................................................................................... 3-50

Touchscreen Controls .................................................................................................. 3-51

Theory of Operations ...................................................................................... 4-1Forming Cycle ........................................................................................................ 4-2Timing Chart .......................................................................................................... 4-3Heat Sealing ........................................................................................................... 4-4Vertical Sealing Cycle ............................................................................................ 4-5Horizontal Sealing Cycle........................................................................................ 4-6Film Registration .................................................................................................... 4-7

Operator Controls ........................................................................................... 5-1Operator Interface .................................................................................................. 5-2

Touchscreen Display and Function Keys ................................................................ 5-3Numeric Keypad and Arrow Keys ............................................................................. 5-4

Operations Screen ................................................................................................. 5-6MOVE FILM Switch .................................................................................................... 5-7JOGGING SELECT Switch ........................................................................................ 5-7BELTS Switch ............................................................................................................. 5-8HEAT Switch ............................................................................................................... 5-8FEEDER Switch .......................................................................................................... 5-8LENGTH Switch ......................................................................................................... 5-9SPEED Switch ............................................................................................................ 5-9SETTINGS Switch ...................................................................................................... 5-9ACT POSITION Display .............................................................................................. 5-9

Table of Contents


3/2000 VPK REV(B) PANELVIEW 600 IV


Settings Screen........................................................................................................ 5-10Cam Settings ......................................................................................................................5-11

Horiz. Cooling Settings ................................................................................................. 5-12Vertical Cooling Settings (if equipped) ......................................................................... 5-12Knife Settings............................................................................................................... 5-13Film Tracking Settings.................................................................................................. 5-13Vibrator ........................................................................................................................ 5-14Bag Folder ................................................................................................................... 5-14

Jaw Seal Settings Screen .................................................................................................. 5-15AUTO/MAN SELECT Switch........................................................................................ 5-15SET SEAL TIME Switch ............................................................................................... 5-15Film Bulge Factor Setting ............................................................................................. 5-16Actual Seal Time Display ............................................................................................. 5-16JAW PROFILE Switch .................................................................................................. 5-16

Jaw Profile Settings Screen ............................................................................................... 5-17AUTO/MAN Switch ...................................................................................................... 5-17Postseal Angle and Postseal Time Settings ................................................................. 5-17Preseal Time Setting .................................................................................................... 5-17

Feeder Screen ................................................................................................................... 5-18Printer Screen .................................................................................................................... 5-20Vertical Seal Screen........................................................................................................... 5-21Photoeye Screen ............................................................................................................... 5-22Stabilo Seal Screen ........................................................................................................... 5-23Recipe Management Screen .............................................................................................. 5-24

Recipe Load Selection Screen ..................................................................................... 5-25Recipe Save Selection Screen..................................................................................... 5-26

Alarms Screen ................................................................................................................... 5-27

Temperature Controllers ..................................................................................... 5-28MAIN DISCONNECT Switch ............................................................................... 5-29AIR DISCONNECT Lever .................................................................................... 5-30Push-Buttons and Selector Switch .................................................................... 5-31

SYSTEM READY Push-Button ................................................................................ 5-31JOG/AUTO Selector Switch .................................................................................... 5-31JOG/RUN Push-Button ............................................................................................ 5-32STOP Push-Button .................................................................................................. 5-32EMERGENCY STOP Push-Button .......................................................................... 5-33

Table of Contents


3/2000 VPK REV(B) PANELVIEW 600 V


Machine Setup Procedures ............................................................................ 6-1Powering the Bagmaker ....................................................................................... 6-2Loading a Product Recipe..................................................................................... 6-3Setting the Machine Speed and Bag Length ....................................................... 6-4Installing the Forming Set...................................................................................... 6-5Loading a Film Roll ................................................................................................ 6-6Threading a Film Roll............................................................................................. 6-7Vertical Seal Setup................................................................................................. 6-8Pneumatic Pressure Settings ............................................................................. 6-10Setting the Film Tension...................................................................................... 6-11Setting the Film Tracking Position ..................................................................... 6-12Positioning the Automatic Film Tracking Sensors ............................................ 6-13Registration Sensor Setup .................................................................................. 6-14

Sensor Setup for Non-Registered Film .................................................................. 6-15Sensor Setup for Registered Film .......................................................................... 6-16

Window In and Offset In Settings ....................................................................................... 6-17Determining the Window In Value ............................................................................... 6-18Determining the Offset In Value.................................................................................... 6-19

Operating Procedures ..................................................................................... 7-1Start-Up .................................................................................................................. 7-2Preparing the Bagmaker ....................................................................................... 7-3Making Empty Bags ............................................................................................... 7-4Making Filled Bags ................................................................................................. 7-6Checking Filled Bags ............................................................................................. 7-7Starting a Production Run..................................................................................... 7-8

Shut Down the Bagmaker ......................................................................................... 7-9Emergency Stop......................................................................................................... 7-9Normal Stop ............................................................................................................... 7-9Extended Shutdown................................................................................................... 7-9

Restart the Bagmaker After an E-Stop .............................................................. 7-10Jog the Bagmaker ............................................................................................... 7-11

Film Feed Jogging ....................................................................................................7-11Jaw Jogging ..............................................................................................................7-11

Table of Contents


3/2000 VPK REV(B) PANELVIEW 600 VI


Working with Components ............................................................................ 8-1Replacing Heater Cartridges and Temp. Probes.................................................... 8-2

Horizontal sealing Jaws .............................................................................................8-2Vertical Sealing Device ...............................................................................................8-5

Replacing the Film Feed Belts ................................................................................ 8-7Replacing the Cutting Knife .................................................................................... 8-8Aligning the Forming Set ........................................................................................ 8-9Aligning the Belt Assemblies ................................................................................ 8-10

Changeover Procedure ................................................................................... 9-1

Maintenance Procedures.............................................................................. 10-1Daily Cleaning ...................................................................................................... 10-2Daily Maintenance ................................................................................................ 10-3Weekly Maintenance ............................................................................................ 10-4

Troubleshooting Guide................................................................................. 11-1

Introduction


3/2000 VPK REV(B) PANELVIEW 600 1-1

IntroductionThe Rovema VPK is a continuous motion form-fill-seal verticalbagmaker that packs a variety of products into bags. It forms, fills,and seals bags by forming flat packaging material into a tube, sealingthe edges and bottom of the tube, filling the tube with product, cuttingthe tube to length, and sealing the top of the tube.

The bagmaker can be equipped with a number of options that canchange a bag�s shape or print information on a bag.

Figure 1.1Shows the standard VPK-260 bagmaker.

Safety Instructions



Safety InstructionsThis section contains information on machine safety issues. Theseissues include:

n Bagmaker Safety Devicesn Component Safetyn Operator Safetyn Machine Lockout Procedure

Safety Instructions



Safety DevicesThe VPK safety devices include guard doors, an EMERGENCY STOPpush-button, and safety labels.

Guard DoorsThe guard doors isolate the operator from the forming and sealingarea. The doors are also equipped with a switch that causes themachine to stop when they are opened.

Figure 1.2Shows the front guard door switch. If your machine is equipped with a sideguard door, there will be a similar switch attached to it.

Door Switch

Safety Instructions



Safety Devices

EMERGENCY STOP Push-ButtonThe EMERGENCY STOP push-button causes the bagmaker toimmediately stop operating if pushed. This push-button should beused when there is perceived or actual damage occurring to thebagmaker or to an operator.

Figure 2.3Shows the EMERGENCY STOP push-button.

EMERGENCY STOPPush-Button

Safety Instructions



Safety Devices

Safety LabelsSafety labels alert an operator to a particular hazard. These labelsappear at various places on the machine. Look for these labels, readthem, and follow their instructions.

Figure 2.4The two top labels indicate areas of the bagmaker that could burn you iftouched. The two bottom labels indicate areas of the bagmaker that couldbreak a limb.

DANGER

PINCH POINTSWATCH YOUR HANDS

CAUTION

HOT SURFACEDO NOT TOUCH

Safety Instructions



Component SafetyRovema does not allow any electrical or mechanical modifications tothe VPK bagmaker without explicit authorization.

Only original Rovema spare parts and accessories should be usedon the bagmaker; This ensures that the machine will perform safelyand as designed.

The user must confirm that the wrapping material (film) will not produceharmful gases during sealing. The film supplier should provide suchassurances.

Safety Instructions



Operator SafetyOnly properly trained personnel can operate the bagmaker. Theoperator is responsible for following the operator safety guidelinespresented in this section as well as any employer safety guidelines.

Operator Safety GuidelinesUse the following safety guidelines for safe operation of the bagmaker.

1. Do not operate the bagmaker until you have read and understoodit�s operating instructions and have become thoroughly familiarwith them.

2. Do not wear rings, loose jewelry, or loose clothing while operatingthe bagmaker.

3. Secure long hair under a hair net or bump cap while operating thebagmaker.

4. Follow the lockout procedure before performing any cleaning,maintenance, or repairs on the bagmaker.

5. Never use the MAIN DISCONNECT switch to stop the bagmaker.

6. Do not remove the guards or open doors except during necessaryadjustments or repairs. Be sure to lockout the bagmaker beforeremoving any guards or doors.

7. Lockout the bagmaker before clearing jaw jams. Never use yourfingers to remove jammed material; Use a tool or a rod.

8. Always wear safety glasses when servicing the bagmaker.

Safety Instructions



Lockout ProceduresThe bagmaker must be properly locked out before any repair ormaintenance tasks can be performed on it. This section describesprocedures that should be used to lockout the air and power supplies.

Air Supply LockoutUse the following procedure to lockout the air supply:

1. Raise the AIR DISCONNECT lever to its horizontal position todisable the air supply to the machine.

2. Remove the lever from the inlet valve.

Figure 2.7Shows how to disable the bagmaker�s air supply and how to remove the AIRDISCONNECT lever.

Safety Instructions



Lockout Procedures

Power Lockout ProcedureUse the following procedure to lockout the electrical power supply:

1. Press the STOP push-button to halt the machine.

2. Turn the MAIN DISCONNECT switch to the OFF position to disableelectrical power to the machine

3. Pull out the lockout handle on the MAIN DISCONNECT switch.

4. Place a lockout tag through the hole in the lockout handle.

5. Place a pad lock through one of the holes in the lockout tag.

6. Attempt to start the bagmaker by turning the MAIN DISCONNECTswitch to the ON position.

If the MAIN DISCONNECT switch will not turn to the ON positionthen the lockout procedure was successful. If the switch will turnto the ON position then the lockout procedure was not successfuland must be performed again.

Pad Lock

MAIN DISCONNECT Switch

Lockout Tag

Lockout Handle

Figure 2.8Shows how to lockout the electrical supply to the bagmaker.

Parts and Functions



Parts and FunctionsThis section describes the major parts and functions of the VPK verticalbagmaker. These parts include the:

n Film Carriagen Film Feeding Devicen Forming Setn Vertical Sealing Devicen Horizontal Sealing Devicen Registration Sensorn Pneumatics Systemn Optional Equipment

Parts and Functions



Film CarriageThe film carriage controls the supply of packaging material that thebagmaker uses to form bags. It includes a:

n Film Spindlen Dancer Assemblyn Film Unwind Braken Film Tracking Assemblyn Out of Film Sensor Assemblyn Guide Rollers

Figure 3.1Shows the components of the film carriage.

DancerAssembly

Guide Roller

Film Spindle

Out of FilmSensor Assembly

Film UnwindBrake Assembly

Film TrackingAssembly

Parts and Functions



Film Carriage

Film SpindleThe film spindle supports the packaging material on the film carriage.It consists of an air bladder that is partially enclosed within a metalhousing. The housing has slots that allow sections of the air bladderto protrude through it. When the bladder is inflated, it protrudes throughthe slots and presses against the inside of the film core; holding thefilm on the spindle. The bladder is inflated and deflated through theair valve located in the end of the spindle.

Figure 3.2Shows the film spindle.

Air Valve

Air Bladder

Parts and Functions



Film Carriage

Dancer AssemblyThe dancer assembly maintains tension on the film web. It includesone fixed roller and a dancer arm assembly. When film is threadedthrough the bagmaker, a film loop forms between the fixed roller andthe arm rollers. As film is pulled out of the film carriage during bagforming, the film loop pulls the dancer arms upward and tensions thearm springs. The tensioned springs cause the dancer arm assemblyto push downward on the film loop. This prevents any slack fromforming in the loop.

Note: Slack in the film web causes film registration and film trackingproblems.

Figure 3.3Shows the dancer assembly.

Dancer Arm

Arm SpringsArm Rollers

Film Loop

Fixed Roller

Parts and Functions



Film Carriage

Film Unwind BrakeThe film unwind brake controls the unwinding of the film roll. It consistsof a brake drum that is attached to the film spindle and a brake padassembly that is actuated by the dancer assembly. As the dancerassembly rises during bag forming, it moves the brake pad away fromthe brake drum; allowing the film roll to unwind. When bag formingstops, the dancer assembly lowers and press the brake pad againstthe brake drum; stopping the film roll from unwinding.

Figure 3.4Shows the film unwind brake.

Brake Drum

Brake Pad

Parts and Functions



Film Carriage

Film Tracking AssemblyThe film tracking assembly controls the position of the film carriagerelative to the forming collar; thus controlling the alignment of thevertical seal. The assembly includes a DC drive motor and two limitswitches. The drive motor moves the upper and lower sections of thefilm carriage towards either side of the forming collar. The limit switcheslimit the movement of the film carriage to just a few inches.

You will make film tracking adjustments to align the edges of the filmtube (vertical seal). It is best if you make your adjustments whilejogging the film feeding device or while running the bagmaker inautomatic mode. This will allow the film web to slide across the guiderollers and the forming collar with ease.

Figure 3.5Shows the film tracking assembly. The limit switches are behind the motor.

Parts and Functions



Film Carriage > Film Tracking Assembly

Touchscreen ControlsThe film carriage movements are controlled by two switches on thetouchscreen display. Whenever the bagmaker is turned on, pressingeither of these switches will cause the film carriage to move (exceptwhen the E-STOP button is depressed). The movements will be slowyet steady.

Figure 3.6Shows the switches that control the film tracking position.

Allen-Bradley PanelView 600AB

7

4

1

8

5

2

9

6

3

. 0 -

F1 F2 F3 F4 F5

F6 F7 F8 F9 F10

MOVE FILM

HEAT V. COOLING

SETTINGS

JOG SELECT

LENGTHF9

LEFTF6

RIGHTF7

FILMF10

MENU F1

ACT. POSITION

###

###

SPEEDF8

###

ENABLEDF4

DISABLEDF5

FEEDER BELTS

DISABLEDF2

CLOSEDF3

Parts and Functions



Film Carriage

Out of Film Sensor AssemblyThe out of film sensor assembly causes the bagmaker to stop formingbags when the film roll is exhausted or when the film tension is toohigh. It consists of a proximity sensor and two metal flags that areconnected to the dancer arms.

When the film roll is exhausted, the dancer arms fall to the bottom ofthe film carriage and rotate the upper flag in front of the proximitysensor. This signals the bagmaker to stop forming bags.

When the film tension is too high, the film loop pulls the dancer armsto the top of the film carriage and rotates the lower flag in front of thesensor. This also signals the bagmaker to stop forming bags.

Figure 3.7Shows the proximity sensor and its two flags.

Lower Flag

Upper Flag

Parts and Functions



Film Carriage

Guide RollersThe guide rollers provide an almost frictionless path for the film totravel along up to the forming collar. The last set of rollers before thecollar (setup rollers) are adjustable. These rollers change the angleof the film web to match the angle of the forming collar. When theseangles do not match, the film web tends to bind as it moves over thecollar.

Figure 3.8Shows how the setup rollers adjust the angle of the film to match the angle ofthe forming collar.

Adjustment Knob

Setup Rollers

Parts and Functions



Film Feeding DeviceThe film feeding device pulls film from the film carriage and pushes itdown the forming tube for sealing. The device consists of two beltsassemblies, a drive system, and an engage/retract device.

Figure 3.9Shows the film feeding device.

Film FeedingDevice

Parts and Functions



Film Feeding Device

Belts AssembliesThe belt assemblies suction the film tube and push it down the formingtube. Within each assembly is a vacuum chamber that directs vacuumthrough holes in the feeding belts. The suction produced by the vacuumincreases the friction between the belts and the film tube while reducingthe friction between the film tube and the forming tube. You can adjustthe amount of pressure that the belt assemblies apply against theforming tube with a pressure regulator and gauge located inside ofthe machine housing.

Figure 3.10Shows a belt assembly with the vacuum chamber exposed.

FeedingBelt

VacuumChamber

VacuumLine

Parts and Functions



Film Feeding Device

Drive SystemThe drive system turns the film feed belts to push the film down theforming tube. The system includes two motors (one for each beltassembly) and two servo amplifiers. The servo amplifiers power thedrive motors and operate them in synchronization.

Figure 3.11Shows the film feeding servo motors and the servo amplifiers.

Film FeedServo Motors

Film FeedServo Amps.

Parts and Functions



Film Feeding Device

Engage/Retract DeviceThe engage/retract device moves the film feeding belts to and fromthe forming tube. It also maintains belt pressure against the tube.The device consists of two pneumatic cylinders, a pressure regulator,and a pressure gauge. Use the pressure regulator and the pressuregauge to adjust and monitor the belt pressure.

You will retract the film feeding device before you thread film throughthe bagmaker or before you remove the forming set. You will engagethe device when you want to form bags or simply advance film downthe forming tube.

Figure 3.12Shows the engage/retract device.

Engage/RetractPneumatic Cylinders

Parts and Functions



Film Feeding Device

Touchscreen ControlsThe film feeding device has one control on the touchscreen display.The BELTS switch controls the engage/retract device. When this switchis set to OPENED, the belts move away from the forming tube. Whenthe switch is set to CLOSED, the belts move against the forming tube.

You will need to open the belts to remove the forming set or threadfilm past the belts. You will need to close the belts when you want tojog the machine or forming bags.

Figure 3.13Shows the bagmaker�s main menu screen and the BELTS OPEN/CLOSEDswitch.


7

4

1

8

5

2

9

6

3

. 0 -

F1 F2 F3 F4 F5

F6 F7 F8 F9 F10

MOVE FILM

HEAT V. COOLING

SETTINGS

JOG SELECT

LENGTHF9

LEFTF6

RIGHTF7

FILMF10

MENU F1

ACT. POSITION

###

###

SPEEDF8

###

ENABLEDF4

ENABLEDF5

FEEDER BELTS

ENABLEDF2

CLOSEDF3

Parts and Functions



Forming SetThe forming set shapes the flat film into a tube and guides productinto the bags. It consists of a forming collar, a forming tube, andsecuring knobs. The forming collar folds the film into a tube. Whiledoing so, it folds one edge of the tube inside out and lays the oppositeedge over it. The forming tube maintains the shape of the folded filmand guides product into the bags. Embedded in the center of theforming tube is a silicon strip. The strip ensures that the vertical sealingband makes full contract with the film. Covering the strip is a piece ofTeflon tape. The tape isolates the forming tube from the heat of thevertical sealing device. The securing knobs hold the forming set tothe machine frame.

The forming set is a changeover item. Each bag style requires adifferent forming set. The forming set can be identified by the numberstamped on the forming collar mount. The number indicates the flatbag width.

Figure 3.14Shows a standard �right over left� pillow style forming set.

Securing Knob

Forming Tube

Forming Collar

Parts and Functions



Vertical Sealing DeviceThe vertical sealing device joins the edges of the film tube together.The device includes: a seal band unit, a drive system, an engage/retract device, and a seal band support.

Figure 3.15Shows the vertical sealing device.

Seal Band Unit

Drive System

Engage/RetractDevice

Seal BandSupport

Parts and Functions



Vertical Sealing Device

Seal Band UnitThe seal band unit joins the edges of the film tube together by meltingthe inner film layer to itself. When the forming set folds the film into atube, it turns a small portion of one edge inside out and lays theopposite edge over it. When heat and pressure are applied to theoverlapping sections for a certain amount of time, they stick together.Only the area under the sealing band is joined.

The seal band unit consists of a heating bar, a sealing band, a bandsensor, and a band release lever.

Figure 3.16Shows the seal band unit.

Release Lever

Band Sensor

Sealing Band

Heating Bar

Parts and Functions



Vertical Sealing Device > Seal Band Unit

Heating BarThe heating bar creates the heat needed to melt the inner film layer.Within the bar are replaceable heating cartridges and a replaceabletemperature probe. A temperature controller on the bagmaker�s controlpanel controls the heating of the bar.

Figure 3.17Shows the heating bar.

Heating Bar

Heating Element

Parts and Functions



Vertical Sealing Device > Sealing Band Unit

Sealing Band, Band Sensor, and Band Release LeverThe sealing band transfers heat from the heating bar to the film tube.The band sensor causes the bagmaker to stop forming bags if theband breaks. The band release lever removes tension from the bandso that it can be removed.

Figure 3.18Shows the sealing band, the band sensor, and the band release lever.

Band Sensor

Release Lever

Sealing Band

Parts and Functions




Drive SystemThe drive system turns the sealing band in synch with the film feedingbelts. This keeps the band stationary with respect to the film andprevents the band from wrinkling the film. The system includes an ACdrive motor, a speed controller, and a gear box. The speed controllerreceives a signal from the motion controller to synchronize themovement of the sealing band to the movement of the film feedingbelts.

Figure 3.19Shows the vertical sealing drive system.

AC motor

Speed Controller

Gear Box

Parts and Functions




Engage/Retract DeviceThe engage/retract device moves the seal band unit against and awayfrom the forming tube. The device uses a pneumatic cylinder to performthe engage and retract movements. Settings on the touchscreencontrol the timing of the movements. A pressure regulator and gauge(located inside of the machine housing) control the sealing pressureproduced by the device. The tilt adjustment screws adjust the sealingband unit parallel to the forming tube.

Figure 3.20Shows the engage/retract device

Vertical SealingPressure Adjustment

Tilt AdjustmentScrew

Pneumatic Cylinder

Parts and Functions




Touchscreen ControlsThe timing of the engage/retract movements are controlled by a switchon the touchscreen display. The device is timed to engage the film###ms before the film feeding device begins advancing the film andto retract from the film ###ms after the film stops moving. This allowssufficient sealing time for the film located in front of the sealing band.

Figure 3.21Shows the vertical seal screen.

VERTICAL SEAL

V. SEAL INDELAY (ms)

V. SEAL OUTDELAY (ms)

####

####

Parts and Functions




Seal Band SupportThe seal band support holds the seal band unit and positions the unitrelative to the forming tube. It includes position locking levers, pivotlocking levers, and lateral adjustment bolts.

Loosen the position locking levers to change the distance betweenthe sealing band and the forming tube. Loosen the pivot locking leversto swing the unit away form the forming tube without changing itsdistance from the tube. Loosen the lateral adjustment bolts to centerthe sealing band on the desired sealing area.

Figure 3.22Shows the seal band support.

PositionLocking Lever

PivotLocking Lever

LateralAdjustment Bolts

PositioningScale

Parts and Functions



Horizontal Sealing DeviceThe horizontal sealing device creates the top and bottom seals in abag and cuts the bag from the film tube. Top and bottom seals(horizontal seals) are created in the same manner as the vertical seal;by applying heat and pressure for a certain amount of time. The heatand pressure are created by the sealing jaws. The time is controlledby the speed of the drive system.

The horizontal sealing device consists of a front and rear jaw assembly,a drive system, and a knife assembly. Controls for the device areaccessed through the touchsrceen display and from the temperaturecontrollers (all located on the bagmaker control panel).

Figure 3.23Shows the components of the horizontal sealing device.

Front JawAssembly

Knife Assembly

Rear JawAssembly

Parts and Functions



Horizontal Sealing Device

Jaw AssembliesThe jaw assemblies create horizontal seals in the film tube. Seal arecreated when the front and back sides of the film tube are pressedtogether and heated for a period of time. The heat causes the innerfilm layer to melt and the pressure causes the two sides of the innerfilm layer to mix and form a bond (seal).

There are two jaw assemblies; a front jaw assembly and a rear jawassembly. The assemblies are identical except that the front jaw housesthe knife assembly and the rear jaw is fitted with alignment screws.Both jaws consist of: a c-frame, a jaw carrier, jaw springs, and a jawbody.

Figure 3.24Shows how the sealing jaws create seals.

Jaw Body

C-Frame

Jaw Carrier

Parts and Functions



Horizontal Sealing Device > Sealing Jaws

Jaw BodyThe jaw bodies create the heat needed to melt the inner film layer.They consist of two halves. The upper half creates bottoms sealswhile the lower half creates top seals. Within each body are tworeplaceable heating cartridge and a replaceable temperature probe.Both the cartridges and the probe are connected to a temperaturecontroller on the bagmaker control panel.

The face of the jaw body shows the jaw body profile. The profile is theimpression that the jaw leaves in the film. The profile increases thestrength of the seal and improves its appearance.

Note: Remove the terminal housing cover to expose the replaceableheating cartridges and the temperature probe.

Figure 3.25Shows the rear jaw body.

Jaw Profile

TerminalHousing

Parts and Functions




C-Frames, Jaw Carriers and Jaw SpringsThe c-frames, the jaw carriers, and the jaw springs work in conjunctionto create the pressure needed to mix the two sides of the inner filmlayer. The c-frames house the jaw springs and the jaw carriers holdthe jaw bodies. When the front and rear jaws close, the c-framescompress the springs against the jaw carriers and the carriers pressthe jaw bodies together. The amount of sealing pressure is determinedby the amount of spring compression.

Figure 3.26Shows the relationship between the jaw carriers, the jaw bodies, and the jawsprings.

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C-Frame

Jaw Carrier

PressureAdj. Bolt

Jaw Body

Jaw Spring

Parts and Functions




Seal PressureThe sealing pressure is determined by the amount of jaw springcompression. The amount of compression is determined by thedistance between the jaw springs and the c-frames. As this distanceincreases, the sealing pressure decreases. As the distance decreasesthe sealing pressure increases.

You can change the sealing pressure by changing the distance �X� asshown in the illustration. However, it is less time consuming to changethe sealing time or the sealing temperature rather than change thesealing pressure if you are experiencing horizontal sealing problems.

Figure 3.28Shows the relationship between spring compression and sealing pressure.

2500

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6000

6500

23 22 21 20 131419 18 17 16 15

Valid for:1) Spring set Lo=110mm and R=114.28 N/mm2) Two spring sets3) Crank throw r=42 (30:50) mm4) Stroke sa=16,5 (8:10:12)mm5) Short screws

Ajustable bolt length "x" in millimetersMeasure "x" must not be less than 14.5mm!

FMaxX

For VPK-260 Only

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Parts and Functions




Drive SystemThe drive system shapes the motion of the sealing jaws (�D-Motion�).It is this motion that causes the sealing jaws to open and close arounda bag. The system includes a servo motor, a servo amplifier, gearing,and crank arms. The servo motor turns the gearing which turns thecrank arms. The rotating crank arms cause the jaws to open andclose.

Figure 3.28Shows how the opening and closing motion of the jaws is formed.

D-Motion

Crank Arm

Parts and Functions



Horizontal Sealing Device > Drive System

Touchscreen ControlsSealing time is determined by the speed of the horizontal sealingdevice. Settings on the touchscreen display control the speed of thedevice. These settings affect the jaw profile. The jaw profile describesthe speed of the sealing jaws at various points in the �D-Motion�. Theseal time setting determines how fast the jaws move through thesealing portion of the �D-Motion� path. The preseal setting determinesthe speed of the jaws as they close on the film tube. The postsealtime and post seal angle settings determine the speed of the jaws asthey move away from the filled bag.

Figure 3.29Shows the jaw profile and jaw seal settings screens.

MAINMENU F1

JAW SEALMENU F7

SETTINGSMENU F2

JAW PROFILE SETTINGS

SET PRESEALTIME F3

SET POSTSEALTIME F4

###

###

AUTO/MANSELECT F6

MANUALF6

POSTSEALANGLE F5 ##

MAINMENU F1

JAW PROFILEMENU F6

SETTINGSMENU F2

JAW SEAL SETTINGS

FILM BULGEFACTOR F4

SET SEALTIME F3

###

###

AUTO/MANSELECT F5

ACTUALSEAL TIME###

AUTOF5

Parts and Functions




Knife AssemblyThe knife assembly cuts the bags from the film tube. It is housed between the upper and lower sections of the front jaw assembly. When the sealing jaws close, the knife extends to cut through the film. It is powered by a pneumatic cylinder. The timing of the cut is controlled by a switch on the touchscreen.

Figure 3.30Shows the knife assembly.

PneumaticCylinder

Parts and Functions



Horizontal Sealing Device > Knife Assembly

Touchscreen ControlsA switch on the touchscreen controls the movements of the cuttingknife. This switch determines when the knife can extend and cut abag from the film tube and whether the knife will be used during bagproduction. Disabling the knife during bag production creates acontinuous string of bags.

Figure 3.31Shows the KNIFE switch.

KNIFE

###

ENABLEDF3

CAM OFF F5

###CAM ON F4

SWITCH

Parts and Functions




Temperature ControllersThe temperature controllers monitor and adjust the horizontal sealingtemperatures. There is one controller for each jaw assembly. Thecontroller applies full voltage to the heating cartridges until the setsealing temperature is reached. Then, it cuts the power to thecartridges. While the temperature controller is on, it continually turnsthe power to the heating cartridges on and off to maintain the settemperature.

Figure 3.32Shows the temperature controllers for the horizontal sealing device (�FRONT�and �REAR�).

Parts and Functions



Registration SensorThe registration sensor allows the bagmaker to use registered film.Because registered film has artwork printed at evenly spaced intervals,the bagmaker must seal the film between the printed sections. In orderfor it to accomplish this, it must detect the location of the printed sectionsand position them relative to the horizontal sealing device.

The bagmaker detects the location of the printed sections by detectingmarks (registration marks) printed at the edge of the film web. Once thebagmaker has referenced the film, it can position the film to be sealedat any location.

In order for the sensor to detect the registration marks, the lens of thesensor must be positioned in the path of the marks. This is accomplishedby using the sensor�s adjustment lever.

Figure 3.33Shows the registration sensor.

Sensor

PositionAdj. Lever

SensorLens

Parts and Functions



Registration Sensor

Touchscreen ControlsThe registration sensor has three switches that control its operation; theWINDOW IN switch, the OFFSET IN switch, and the ENABLE/DISABLEswitch. The WINDOW INswitch determines when the bagmaker willexamine the signal from the sensor; this prevent false readings createdby artwork printed around the registration marks. The OFFSET IN switchoffsets the sealing operation when the registration marks are not locatedat the desired sealing location. The ENABLE/DISABLE switchdetermines if the bagmaker can us the sensor during bag forming.

Note: The ENABLE/DISABLE switch must be set to DISABLE whenthe bagmaker is using non-registered film.

Figure 3.34Shows the touchscreen controls for the registration sensor.

DISABLEDF6SWITCH

###OFFSET IN(mm) F8

###WINDOW IN(mm) F7

PHOTOEYE

Parts and Functions



Pneumatics SystemThe pneumatics system controls the compressed air supply to thebagmaker. The system distributes compressed air to the bagmaker�spneumatic cylinders, the vacuum generator, and the cooling devices.The system includes a primary manifold and an air filter/regulator.

Figure 3.35Shows the pneumatics system. The air filter regulator is located on the filmcarriage.

Parts and Functions



Pneumatics System

Primary ManifoldThe primary manifold distributes compressed air to the horizontal andvertical cooling devices, the vacuum system and the solenoid bank.A pressure switch is also connected to the primary manifold.

Figure 3.36Shows the primary manifolds.

PrimaryManifold

Parts and Functions



Pneumatic System

Pressure SwitchThe pressure switch monitors the available air pressure in the primarymanifold. If the pressure falls below the preset limit, the switch signalsthe bagmaker to stop forming bags and to display the �LOW AIRPRESSURE� alarm message on the touchscreen. Once the airpressure is restored and the ALARM RESET switch is pressed (onthe touchscreen) the alarm will be cleared.

The low air pressure limit is typically set around 60 PSI. The limit isset using the knob on top of the pressure switch.

Figure 3.37Shows the pressure switch.

PressureSwitch

Pressure LimitAdjustment

Parts and Functions



Pneumatics System

Horizontal and Vertical Cooling DevicesThe horizontal and vertical cooling devices release compressed aironto the horizontal and vertical seals. These devices directcompressed air from the primary manifold, through valves, throughair lines, to cooling wands. The valve for the horizontal cooling deviceis a pressure regulator with a pressure gauge. The amount of horizontalcooling is set using the regulator�s adjustment knob. The pressuregauge allows for precise adjustments. The valve for the vertical sealingdevice is a flow control valve. The amount of vertical cooling is setusing the valve�s adjustment knob.

Note: There is no pressure gauge for the vertical cooling devicebecause the amount of air flow is not as critical as it is for thehorizontal cooling device.

Figure 3.38Shows the horizontal and vertical cooling valves.

HorizontalCooling

VerticalCooling

Parts and Functions



Pneumatics System

Vacuum SystemThe vacuum system creates the suction for the film feeding beltassemblies. The system includes a vacuum generator, an air filter,and a vacuum gauge. The vacuum generator uses compressed air togenerate a vacuum. The vacuum is directed through the air filter, pastthe vacuum gauge, and to the film feeding belt assemblies. The airfilter removes film debt from the system. The gauge is used to verifythat the system is functioning properly. When the system is functioningproperly, the gauge should read above 10 Hg (20 Hg for 360 models).

Figure 3.39Shows the vacuum system.

Air Filter

VacuumGauage

VacuumGenerator

Parts and Functions



Pneumatics System

Solenoid BankThe solenoid bank supplies compressed air to all of the bagmaker�spneumatic cylinders. The PLC activates each solenoid valve in thebank at a specific time to perform a forming operation.

Figure 3.40Shows the solenoid bank.

SolenoidBank

Parts and Functions



Optional EquipmentOptional equipment enhances the capabilities of the bagmaker. Thisequipment includes:

n Bevel Platesn Bag Grippersn Foam Deflatorsn Splice Tablen Automatic Film Tracking Sensorn Gusseting Devicen STABILO Sealing System

Parts and Functions



Optional Equipment

Bevel PlatesThe bevel plates isolate the horizontal seals from the impact of theproduct drop. Because they hold the product drop above the horizontalseals, they also allow the seals additional cooling time.

Bag GrippersBag grippers pinch the film tube above and below the horizontal sealingjaws. This allows the seals to be created in a stress free environment.

Foam DeflatorsFoam deflators push the air out of the bags to prevent them frombursting when the bag grippers pinch the film tube closed. They arepositioned slightly ahead of the bag grippers. So, before the baggrippers close, the foam deflators push the excess air in a bag up theforming tube.

Figure 3.41Shows the bevel plates, the bag grippers, and the foam deflators.

Foam Deflator

Bag Gripper

Bevel Plate

Parts and Functions



Optional Equipment

Splice TableThe splice table is used to attach the beginning of a full film roll to theend of an exhausted film roll. When the bagmaker runs out of film, theout of film sensor causes the bagmaker to stop forming bags and ittriggers the automatic clamping bar to grab the film end before it leavesthe film carriage. Once a new roll of film is loaded on the film carriageand threaded up to the splice table, the manual clamping bar is usedto hold the end of the new film roll while the two film ends are tapedtogether.

Figure 3.42Shows the splice table.

ManualClamping Bar

AutomaticClamping Bar

Parts and Functions



Optional Equipment

Automatic Film Tracking SensorsThe automatic film tracking sensors keep the edges of the vertical seal aligned. There are two optical sensors; one positioned just inside of the film web (inner sensor) and one positioned just outside of the film web (outer sensor). If the film web drifts to the right and the inner sensor becomes unblocked, the bagmaker moves the film carriage towards the left until the sensor is blocked again. If the film web drifts to the left and the outer sensor becomes blocked, the bagmaker moves the film carriage towards the right until the sensor is unblocked again.

Figure 3.43Shows the automatic film tracking sensors.

Inner and OuterOptical Sensors

Parts and Functions



Optional Equipment > Auto. F. Tracking Sensors

Touchscreen ControlsSwitches on the touchscreen display determine when the bagmakercan perform automatic film tracking adjustments. When the jaw driveencoder count is between the cam values, the motion controller signalsthe PLC to perform any necessary film tracking adjustments.

Figure 3.44Shows the film tracking screen.

AUTO FILM TRACKING

###

ENABLEDF6

CAM OFF F8

###CAM ON F7

SWITCH

Parts and Functions



Optional Equipment

Bag Shaping DevicesThe VPK bagmaker can be equipped with two devices that alter theshape of a bag; a gusseting device and a STABILO sealing device.

Figure 3.45Shows a flat bottom bag with gussets and STABILO seals.

Gusset

STABILO Seal

Parts and Functions



Optional Equipment > Bag Shaping Devices

Gusset DeviceThe gusset device adds extra folds in the film tube to create a bagthat will stand on its bottom. There are two types of gusseting devices;mechanical and pneumatic. Both include gusset plows and gussetfingers. The plows created folds in the bottom of the bags while thefingers created folds in the top of the bags. The mechanical gussetingdevice is actuated by the crank arms. The pneumatic gusseting deviceis actuated by air and is controlled by a switch on the touchscreen.

Figure 3.46Shows a pneumatic gusseting device. The gusset fingers are located belowthe sealing jaws.

Gusset Plow

Gusset Finger

Parts and Functions



Bag Shaping Devices > Gusset Device

Touchscreen ControlsThe touchscreen controls for the gusset device determine when thegusset plows and fingers will be extended to fold the film. The deviceis timed so that the gusset folds are formed by the time the jaws touch.

Figure 3.47Shows the gusset screen for a pneumatic gusseting device.

GUSSET

###

ENABLEDF3

CAM OFF F8

###CAM ON F7

SWITCH

Parts and Functions



Optional Equipment > Bag Shaping Devices

STABILO SEAL® Sealing SystemThe STABILO SEAL® sealing system creases the corners of the filmtube. The system includes four corner sealing units. Each unit has astationary sealing rail and a heated sealing jaw. The sealing rails arepositioned behind the corners of the film tube while the sealing jawsare positioned in front of the corners. As the film moves down theforming tube to the sealing jaws, it is pressed between the heatedsealing jaw and the stationary sealing rail. This creases the cornersof the square film tube and creates the STABILO SEAL®.

Figure 3.48Shows the STABILO SEAL® sealing system.

Sealing Jaw Sealing Rail

Cooling

PneumaticCylinder

Parts and Functions



Bag Shaping Devices > STABILO Sealing Device

Touchscreen ControlsThe sealing system has two switches on the touchscreen display. TheHEAT switch toggles the power to the STABILO temperature controllerson and off. The SEAL switch enables and disables the system.

ENABLEDF6

ENABLEDF7

STABILO SEAL

HEATSWITCH

SEALSWITCH

Figure 3.49Shows the STABILO SEAL screen.

Theory of Operations



Theory of OperationsThis section describes the theory behind the forming cycle, heatsealing, the vertical sealing cycle, the horizontal sealing cycle, andfilm registration.




Forming CycleThe forming cycle is based on a 360 degree virtual encoder count(resolver count). During one revolution of the horizontal sealing jaws,all of the forming operations occur once. Most of the operations startand stop at a specific degrees of rotation. When the encoder count isbetween a forming operation�s on/off cam values, the motion controllersignals the PLC to activate that operation.

The vertical sealing device engage/retract movements and the productdump request are forming operations that do not rely on the encodercount. The vertical sealing device engages the film tube a fewmilliseconds before the film feeding device starts advancing film andretracts from the film tube a few milliseconds after film feeding stops.The product dump request is sent a few milliseconds before thehorizontal sealing jaws close.







Heat SealingHeat sealing is the process of bonding two sections of laminated film.Laminated film is constructed of at least two layers of material: anouter layer and an inner layer. The outer layer forms the support andprotective structure of a bag. The inner layer contains the adhesivethat will bond the sides of the outer layer together. Seals are createdwhen sections of the inner layer are pressed together and heated.The heat melts the adhesive while the pressure mixes the adhesiveinto one layer.

Sealing time, sealing temperature, and sealing pressure are the threevariables that govern the creation of horizontal and vertical seals. Whenthe SEAL MODE switch on the jaw profile screen is set to AUTO, thebagmaker will determine the best sealing time. The sealing pressure isset at the factory and should be sufficient for most heat sealingapplications. This leaves the sealing temperature setting as the mostuseful tool that the operator can use to affect the quality of the horizontaland vertical seals. When adjusting the sealing temperature, here aresome facts to keep in mind: The minimum temperature required to meltthe adhesive layer is approximately 180 Degrees. Temperatures above350 Degrees tend to burn most laminated films. We suggest that youset the temperature to around 280 Degrees and increase it towards320 Degrees until the bagmaker is producing good seals. If you areunable to produce good bags at below 320 Degrees, adjustments mayhave to be made to the sealing time and/or the sealing pressure.

Note: It is recommended that you set the SEAL MODE switch on thejaw profile screen to AUTO. If you are unable to achieve qualityseals by changing the sealing temperature, contact the RovemaService Department for assistance.




Vertical Sealing CycleThe vertical sealing cycle starts just before the film starts moving. Thevertical sealing device is timed to engage the film tube a few millisecondsbefore the film feeding device begins advancing film. This allowssufficient sealing time for the film position in front of the sealing band.When the device engages the film, it presses the rotating sealing bandagainst the overlapping sections of film. Because the band and the filmmove at the same rate, the band is always stationary with respect to thefilm. This prevents the vertical sealing device from wrinkling the film.When the film stops moving, the seal band stops and remains extendedfor a few milliseconds, then it retracts.




Horizontal Sealing CycleThe horizontal sealing cycle begins when the film starts moving. Thehorizontal sealing device operates at a speed that will allow it to createa specific number of bags each minute. As the sealing jaws close onthe film, they push the front and back sides of the film tube together.As the crank arms drive the c-frames closer together, the c-framescompress the jaw springs against the jaw carriers. The jaw carrierstransfer this force to the jaw bodies. The jaw bodies transfer the forceto the film. The heat and pressure cause the adhesive layer to holdthe front and back sides the outer film layer together.

During the horizontal sealing cycle, two other forming operationstypically occur; cutting and cooling. Just as the sealing jaws close onthe film tube, the motion controller signals the PLC to activate theknife. The knife cuts the film tube between the top seal of the bagbelow the sealing jaws and the bottom seal of the bag above the jaws.As the sealing jaws open, the motion controller signals the PLC toactivate the cooling device. The cooling device release coolcompressed air onto the newly created horizontal seals.




Film RegistrationThe registration sensor allows the bagmaker to use registered film. Registered film is designed to be sealed at specific locations. To accomplish this, the bagmaker must identify these locations and time the sealing jaws to land on them. The locations are identified by marks printed along the edge of the film web (registration marks). When the JOG/RUN push-button is pressed, the bagmaker advance the film web until it detects one of these marks. Then, it moves the sealing jaws into the fully open position. Once the film has been registered and the sealing jaws have been homed, the bagmaker starts the forming cycle. During the cycle, it advances the film and times the sealing jaws to land on it after the bag length has been feed. When this sealing location is not the desired sealing location, the PHOTOEYE CORRECTION switch (on the photoeye screen) can make the bagmaker advance more film to change the sealing location.

When there are other markings on the film that can be mistaken asregistration marks, the PHOTOEYE WINDOW switch (on the photoeyescreen) can prevent the bagmaker from detecting these markings. Itallows the markings to pass the registration sensor before allowing thebagmaker to examining the signal from the sensor.

mwhitmore

Typewritten Text

mwhitmore

Typewritten Text

mwhitmore

Typewritten Text

s

Operator Controls



Operator ControlsThis section describes the controls used to operate the bagmaker.These controls include a touchscreen display, temperature controllers,a MAIN DISCONNECT switch, an AIR DISCONNECT lever, severalpush-buttons, and a selector switch.

Figure 5.1Shows the main control panel.

Operator Controls



Operator InterfaceThe operator interface is used to load, run, or modify a product recipe;and to monitor bag production. The interface consists of a touchscreendisplay, a numeric keypad, a function keypad, and arrow keys.

Figure 5.2Shows the parts of the operator interface.


7

4

1

8

5

2

9

6

3

. 0 -

F1 F2 F3 F4 F5

F6 F7 F8 F9 F10

MOVE FILM

HEAT V. COOLING

SETTINGS

JOG SELECT

LENGTHF9

LEFTF6

RIGHTF7

FILMF10

MENU F1

ACT. POSITION

###

###

SPEEDF8

###

ENABLEDF4

DISABLEDF5

FEEDER BELTS

DISABLEDF2

CLOSEDF3

Operator Controls



Operator Interface

Touchscreen Display and Function KeysThe touchscreen collects and displays information. The display iscomposed of screens. Each screen is a collection of touch sensitivecells that initiate machine functions, change product recipes, activateadditional screens, or display information.

Both the touchscreen and the function keys are used to select amachine function. A function is selected by pressing its coloredtouchcell or by pressing its corresponding function key.

Figure 5.3Shows the touchscreen and the function keys.


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1

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. 0 -

F1 F2 F3 F4 F5

F6 F7 F8 F9 F10

MOVE FILM

HEAT V. COOLING

SETTINGS

JOG SELECT

LENGTHF9

LEFTF6

RIGHTF7

FILMF10

MENU F1

ACT. POSITION

###

###

SPEEDF8

###

ENABLEDF4

DISABLEDF5

FEEDER BELTS

DISABLEDF2

CLOSEDF3

Or

Operator Controls



Operator Interface

Numeric KeypadThe numeric keypad is used to change a function�s value. When afunction has an editable value, an input dialog box will appear on thetouchscreen. Once the new value is entered into the dialog box andthe ENTER key is pressed, the new value will replace the old value.

If you want to correct a value before pressing the ENTER key, pressthe ESC key until the value has been deleted from the input dialogbox. The ESC key can also be used to abort a value change. To aborta value change, simply press the ESC key until the input dialog boxdisappears.

Figure 5.4Shows how to enter function values.


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2

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. 0 -

F1 F2 F3 F4 F5

F6 F7 F8 F9 F10

MOVE FILM

HEAT V. COOLING

SETTINGS

JOG SELECT

LENGTHF9

LEFTF6

RIGHTF7

FILMF10

MENU F1

ACT. POSITION

###

###

SPEEDF8

###

ENABLEF4

ENABLEF5

FEEDER BELTS

ENABLEF2

CLOSEDF3

0(Enter a value between 0 - 359)

ESC Key

Input DialogBox

ENTERKey

Operator Controls



Operator Interface

Arrow KeysThe arrow keys are used with the recipe management screens. Theyallow you to scroll through a list of product recipes to load or save.They are also used to change the name of a product recipe.

Note: The LEFT and RIGHT arrow keys are not used.

Figure 5.5Shows how the up and down arrow keys are used.


7

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2

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F1 F2 F3 F4 F5

F6 F7 F8 F9 F10

MAINMENU F1

CURRENT LOADED

######################################

SETTINGSMENU F2

SELECTRECIPE

TOLOAD

NEWRECIPELOADED

1- ######################################2- ######################################3- ######################################4- ######################################5- ######################################6- ######################################7- ######################################8- ######################################9- ######################################

10- ######################################11- ######################################12- ######################################

Operator Controls



Operator Interface

Operations ScreenThe operations screen displays the most commonly used touchcellsand provides access to all other screens. The cells (switches) on thisscreen include the:

n MOVE FILM Switchn JOG SELECT Switchn HEAT Switchn FEEDER Switchn BELTS Switchn LENGTH Switchn SPEED Switchn SETTINGS Switchn ACT POSITION Display

Figure 5.6Shows the operations screen.


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F1 F2 F3 F4 F5

F6 F7 F8 F9 F10

MOVE FILM

HEAT V. COOLING

SETTINGS

JOG SELECT

LENGTHF9

LEFTF6

RIGHTF7

FILMF10

MENU F1

ACT. POSITION

###

###

SPEEDF8

###

ENABLEF4

ENABLEF5

FEEDER BELTS

ENABLEF2

CLOSEDF3

Operator Controls



Operator Interface > Operations Screen

MOVE FILM SwitchUse this switch to control the film tracking position. Press the LEFTswitch to move the film carriage (and the film web) towards the left-hand side of the forming collar. Press the RIGHT switch to move thefilm carriage (and the film web) towards the right-hand side of theforming collar.

You will need to make film tracking adjustments to align the edges ofthe vertical seal. It is best if you make your adjustments while joggingthe film feeding device or while running the bagmaker in automaticmode. This will allow the film web to slide across the guide rollers andthe forming collar with ease.

JOGGING SELECT SwitchUse this switch to select the machine-jogging mode. Press this switchto toggle between FILM, JAWS FWD, and JAWS REV. When thisswitch is set to FILM and the JOG/RUN push-button is press, the filmfeeding device will advance film down the forming tube without runningthe horizontal sealing device. When this switch is set to JAWS FWDand the JOG/RUN push-button is pressed, the horizontal sealing devicewill cycle forwards without running the film feeding device. When thisswitch is set to JAWS REV and the JOG/RUN push-button is pressed,the horizontal sealing device will cycle backwards without running thefilm feeding device.

Machine jogging is used to setup the bagmaker. Jog the film feedingdevice (FILM switch) when you want to advance film down the formingtube. Jog the horizontal sealing device (JAWS FWD or JAWS REVswitch) when you want to open or close the sealing jaws.

Note: The bagmaker will not jog until the JOG/AUTO selector switchis set to JOG.

Operator Controls




BELTS SwitchUse this switch to open or close the film feed belts. When this switchis set to OPEN, the film feeding belts move away from the formingtube. When this switch is set to CLOSED, the film feeding belts moveagainst the forming tube.

You will open the film feeding belts when you want to remove theforming set or thread film down the forming tube. You will close thebelts when you want to jog the film feeding device or form bags.

HEAT SwitchThis switch toggles the power to the horizontal and vertical temperaturecontrollers on and off. When this switch is set to ENABLED, thetemperature controllers turn on and the horizontal and vertical sealingdevices heat. When this switch is set to DISABLED, the temperaturecontrollers turn off and the sealing devices begin to cool.

Note: This switch does not affect the temperature controllers foroptional equipment (i.e. zipper applicators). These devices willhave a separate switch on the touchscreen display.

FEEDER SwitchThis switch allows or prevents product drops from the product feeder.When this switch is set to ENABLED, the product feeder can releaseproduct charges into the bagmaker filling tube during bag forming.When this switch is set to DISABLED, the product feeder will remainidle during bag forming.

Note: This switch should be set to DISABLED during bagmaker setupto prevent inadvertent product dumps.

Operator Controls




LENGTH SwitchThis switch sets the machine bag length. Pressing this switch displaysa input dialog box. Use the numeric keypad to input the desired baglength in millimeters.

SPEED SwitchThis switch sets the machine operating speed. Pressing this switchdisplays a input dialog box. Use the numeric keypad to input thedesired operating speed in bags/minute.

SETTINGS SwitchThe settings switch activates the settings screen. Press this switchonce to activate the settings screen.

ACT POSITION DisplayThis cell displays the cycle position (0-359 Degrees) of the horizontalsealing device.

Operator Controls



Operator Interface

Settings ScreenThe settings screen contains switches that control forming operations,recipe management, and data monitoring.

Figure 5.7Shows the settings screen.

PHOTOEYEMENU

H.COOL/STABILO MENU

PRINTERSETUP MENU

V. SEAL/F. TRACK MENU

FEEDER/KNIFEMENU

CAM 9/CAM 10 MENU

JAWS SETUPMENU

MAINMENU F1

RECIPEMENU F2

SERVICEMENU F3

ZIPPERSETUP MENU

VIBRATOR/DISCH. MENU

Operator Controls



Operator Interface > Settings Screen

Cam SettingsMany of the screens under the settings screen control cam settings.Cam settings determine when forming operations will occur based onthe position of the horizontal sealing jaws. The position of the sealingjaws are tracked by a 360 Degree �virtual encoder�. When the encodercount is between the cam values set for a forming operation, the motioncontroller signals the PLC to initiate that operation. Some cam settingshave ENABLED/DISABLED switches. An ENABLED/DISABLEDswitch tells the PLC whether or not a forming operation can be activatedduring bag forming. So, for example, if you do not want the bag vibratorto vibrate the bags during bag forming, set its ENABLED/DISABLEDswitch to DISABLED.

Figure 5.8Shows the cam switches that control the bag vibrator and the bag dischargeunit.

MAINMENU F1

PREVIOUSMENU F2

VIBRATOR BAG DISCHARGE

ENABLEDF6

150

230

SWITCHENABLED

F3SWITCH

CAM ON F7

CAM OFF F8

300

30

CAM ON F4

CAM OFF F5

ACT POSITION

0

Operator Controls



Op. Interface > Settings Screen > Cam Settings

Horiz. Cooling SettingsThese settings determine when the horizontal cooling device can beactivated to cool horizontal seals. When the encoder count is betweenthese settings, the motion controller will signal the PLC to energizethe horizontal cooling solenoid valve. When the valve is energized,cool air is released onto the horizontal seals.

Figure 5.9.1Shows the horizontal cooling screen.

Vertical Cooling Settings (if equipped)These settings determines when the vertical cooling device can beactivated to cool the vertical seal. When the encoder count is betweenthese settings, the motion controller will signal the PLC to energizethe vertical cooling solenoid valve. When the valve is energized, coolair is released onto the vertical seal.

Figure 5.9.2Shows the vertical cooling screen.

HORIZ. COOLING

###

ENABLEDF3

CAM OFF F5

###CAM ON F4

SWITCH

VERTICAL COOLING

###

ENABLEF6

CAM OFF F8

###CAM ON F7

SWITCH

Operator Controls



Op. Interface > Settings Screen > Cam Settings

Knife SettingsThese settings determine when the knife can be extended to cut abag from the film tube. When the encoder count is between thesesettings, the motion controller will signal the PLC to energize the knifesolenoid valve. When the valve is energized, the knife will cut acrossthe film tube.

Figure 5.10.1Shows the knife screen.

Film Tracking SettingsThese settings determine when the PLC can make automatic filmtracking adjustments. When the encoder count is between thesesettings, the motion controller will signal the PLC to move the filmcarriage left or right to keep the edges of the vertical seal aligned.

Figure 5.10.2Shows the auto film tracking screen.

KNIFE

###

ENABLEDF3

CAM OFF F5

###CAM ON F4

SWITCH

AUTO FILM TRACKING

###

ENABLEDF6

CAM OFF F8

###CAM ON F7

SWITCH

Operator Controls



Op. Interface>Settings Screen>Cam Settings

VibratorThese settings determine when the bag vibrator can be activated tosettle the product in the bag. When the encoder count is betweenthese settings, the motion controller will signal the PLC to energizethe vibrator solenoid valve and the vibrator will shake the bag. Typicallythis occurs as the bag is being cut from the film tube.

Figure 5.11.1Shows the vibrator screen.

Bag FolderThese settings determine when the bag folder can be extended tofold the bottom seal against the bottom of the bag. When the encodercount is between these settings, the motion controller will signal thePLC to energize the bag folder solenoid valve and the folder will extend.Just as the sealing jaws close, the edge of the folder should touch thebottom seal and begin folding it.

Figure 5.11.2Shows the bag folder screen

VIBRATOR

ENABLEDF3SWITCH

###

###

CAM ON F4

CAM OFF F5

BAG DISCHARGE

ENABLEDF6

###

###

SWITCH

CAM ON F7

CAM OFF F8

Operator Controls




Jaw Seal Settings ScreenThis screen contains switches that control the speed of the sealingjaws as the move through the sealing portion of the �D-Motion� path(sealing cycle) and a switch that affects the speed of the film relativeto the speed of the sealing jaws.

AUTO/MAN SELECT SwitchThis switch toggles the jaw seal mode between automatic and manual.When set to AUTO, the bagmaker determines the seal time parameter.When set to MAN, the operator must determine the seal timeparameter.

Note: For most bagmaker applications, set this switch to AUTO forthe best results.

SET SEAL TIME SwitchSeal time is the amount of time that the sealing jaws will stay in contactwith the film tube to create horizontal seals. Its value will depend onthe sealing pressure and sealing temperature of your film.

Figure 5.12Shows the jaw seal settings screen.

MAINMENU F1

JAW PROFILEMENU F6

SETTINGSMENU F2

JAW SEAL SETTINGS

FILM BULGEFACTOR F4

SET SEALTIME F3

###

###

AUTO/MANSELECT F5

ACTUALSEAL TIME###

AUTOF5

Operator Controls



Op. Interface > Set Scrn > Jaw Seal Settings

Film Bulge Factor SettingThis setting causes the film feeding device to run some percentageslower or faster than the horizontal sealing device. Bulge factorsbetween 80% and 100% cause the film to move slower than the sealingjaws which stretches the bags downward during filling. Bulge factorsbetween 100% and 120% cause the film to move faster than the sealingjaws which expands the bags outward during filling.

Actual Seal Time DisplayThis display cell shows the seal time value that the bagmaker calculateswhen the AUTO/MAN SELECT switch is set to AUTO. When the AUTO/MAN SELECT switch is set to MAN, it shows the value set for theSET SEAL TIME switch.

Figure 5.13Shows the jaw seal settings screen.

JAW PROFILE SwitchThis switch displays the jaw profile settings screen which controls thespeed of the sealing jaws before and after the sealing cycle.

MAINMENU F1

JAW PROFILEMENU F6

SETTINGSMENU F2

JAW SEAL SETTINGS

FILM BULGEFACTOR F4

SET SEALTIME F3

###

###

AUTO/MANSELECT F5

ACTUALSEAL TIME###

AUTOF5

Operator Controls



Op. Interface > Settings Scrn > J. Profile Setings

AUTO/MAN SwitchThis switch toggles the jaw profile mode between automatic andmanual. When set to AUTO, the bagmaker calculates the postsealtime, the postseal angle, and the preseal time. When set to MAN, theoperator must determines these parameters.

Note: For most bagmaker applications, set this switch to AUTO forthe best results.

Postseal Angle and Postseal Time SettingsThe postseal angle is the angle that the sealing jaws travel throughafter they have created a seal. The postseal time is the amount oftime the jaws have to travel through the postseal angle. Together,these two settings determine the speed of the jaws as they moveaway from the sealing area.

Preseal Time SettingThe preseal time is the amount of time that the jaws have to movefrom the top of the jaw stroke to the film. This setting controls thespeed of the jaws as they move toward the film.

Figure 5.14Shows the jaw profile screen.

MAINMENU F1

JAW SEALMENU F7

SETTINGSMENU F2

JAW PROFILE SETTINGS

SET PRESEALTIME F3

SET POSTSEALTIME F4

###

###

AUTO/MANSELECT F6

MANUALF6

POSTSEALANGLE F5 ##

Operator Controls




Feeder ScreenThe feeder screen synchronizes the bagmaker and the product feeder.It also determines the method of synchronization between the twomachines. The drop time setting synchronizes the release of productfrom the product feeder with the closing of the sealing jaws. Themotion controller is programmed so that ### ms before the horizontalsealing jaws close, it signals the PLC to request a product drop fromthe product feeder. By the time the product drop is requested andreaches the sealing jaws the jaws have closed and the product landson top of them.

Figure 5.15Shows the feeder screen.

DROP TIME(ms) F4

SYNC MODESELECT F5 *

FEEDER

####

Operator Controls



Operator Interface > Settings ScreenThe SYNC MODE SELECT switch activates a screen where you canchoose the method of synchronization; Stroke on Demand orMaster/Slave.

Note: Before the screen is displayed a password is required.

When Stroke on Demand synchronization is used, the product feederconstantly sends a status signal to the bagmaker. The signal tells thebagmaker whether the product feeder is ready to release a productcharge. Just before the bagmaker is ready to receive a charge, itexamines the signal. If the signal indicates that the feeder is ready torelease a charge, the bagmaker sends a �dump request� signal to thefeeder and then proceeds to make a bag. If the signal indicates thatthe feeder is not ready to release a product charge, the bagmakerstops the forming cycle.

When Master/Slave synchronization is used, the bagmaker sends a�dump request� signal to the product feeder just before it is ready tomake a bag. If the feeder is ready to release a product charge, itsends a �dump confirmation� signal to the bagmaker and then itreleases a charge. When the bagmaker receives the �dumpconfirmation� signal, it makes a bag in time to receive the productcharge. If the bagmaker does not receive a �dump confirmation� signal,then it stops the forming cycle.

Figure 5.16Shows the sync mode select screen.

MAINMENU F1

SETTINGSMENU F2

STROKE ONDEMAND

SELECTED F3

THE SCALE SYNC MODE SELECTED ON THISSCREEN MUST MATCH THE SYNC MODE

SELECTED IN THE SCALE. ERRATIC MACHINEOPERATION WILL RESULT IF SETTINGS DO

NOT MATCH.

SELECT F3

REQUIRED SCALE SETTINGS FOR MASTER/SLAVE SYNC:DUMP CONFIRM DELAY = 0 ms

DUMP CONFIRM HOLD = 200 ms

Operator Controls



Operator Interface > Settings Menu

Printer ScreenThe settings on this screen determine when the printing device canprint manufacture information on the film. There are three switcheson this screen; an ENABLED/DISABLED switch, an OFFSET switch,and a CAM ON/CAM OFF switch. The ENABLED/DISABLED switchdetermines whether the printer can be activated during bag forming.The OFFSET switch determines when the printer can be activated.

When the printer is enabled, and after ###mm of film has been feedpast the printer, the motion controller will signal the PLC to activatethe printer.

The CAM ON/CAM OFF switch is only used when the zipper applicatorhas been physically removed from the bagmaker.

Note: Please consult the Rovema Service Department beforeremoving the zipper applicator.

Figure 5.17Shows the printer screen.

ENABLEDF4

MAINMENU F1

PREVIOUSMENU F2

PRINTER

CAM ONDEG. F7

OFFSETMM F5

FILM TRAVEL mm: USE WITHZIPPER

CAM SETTINGS: USE W/OZIPPER

CAM OFFDEG. F8

### ###

###SWITCH

ACT POSITION

###

Operator Controls



Operator Interface > Settings Menu

Vertical Seal ScreenThis screen controls the movements of the vertical seal engage/retractdevice. The v. seal in delay setting determines when the vertical sealingdevice will engage the film tube. The v. seal out delay settingdetermines when the vertical sealing device will retract from the filmtube. The v. seal in delay setting engages the device ### ms beforethe film starts moving and keeps it engaged until the STOP push-button is pressed. Once the film feeding device stops, the v. seal outdelay setting keeps the vertical sealing device engaged for ###ms.The delay settings allow the film directly in front of the sealing bandsufficient sealing time before the film starts moving and after it stops.

Figure 5.18Shows the vertical seal screen.

VERTICAL SEAL

V. SEAL INDELAY (ms)

V. SEAL OUTDELAY (ms)

####

####

Operator Controls




Photoeye ScreenThis screen controls the operation of the registration sensor. The�window in� setting determines when the motion controller will examinethe signal from the registration sensor. This prevents the sensor fromdetecting artwork that is printed in the same path as the registrationmarks. The �offset in� setting offsets the sealing operation by ###millimeters. When the bagmaker is not sealing the film at the correctlocation, the �offset in� setting makes the bagmaker advance the filmweb to the correct sealing location before creating seals in the film tube.

Figure 5.19Shows the photoeye screen.

DISABLEDF6SWITCH

###OFFSET IN(mm) F8

###WINDOW IN(mm) F7

PHOTOEYE

Operator Controls




Stabilo Seal ScreenThis screen controls the operation of the STABILO SEAL® sealingsystem. The HEAT switch toggles the power to the stabilo temperaturecontrols on and off. The SEAL switch enables and disables the sealingsystem. If you are not creating stabilo bags, set this switch toDISABLED.

Figure 5.20Shows the stabilo seal screen.

ENABLEDF6

ENABLEDF7

STABILO SEAL

HEATSWITCH

SEALSWITCH

Operator Controls




Recipe Management ScreenThe recipe management screen includes switches that allow you toload or save a product recipe. Product recipes contain all of the settingsrequired to form a particular bag style.

Note: Before you are allowed to save a recipe, you must enter a fourdigit password. This prevents an unauthorized users fromsaving over a previously saved recipe.

Figure 5.21Shows the recipe management screen.

MAINMENU F1

SETTINGSMENU F2

RECIPE MANAGEMENT

LOAD NEWRECIPE F3

LOADF3

SAVE NEWRECIPE F4 *

ENTER THE FOURDIGIT PASSOWRDTO ACCESS THE

SAVE NEWRECIPE SCREEN

Operator Controls



Op. Interface > Settings Screen > Recipe Mang.

Recipe Load Selection ScreenThis screen is used to load a product recipe. Loading a recipe removesall of the current settings and replaces them with the new settings. Toload a recipe, use the UP and DOWN arrow keys to scroll throughand select a product recipe from the list. Press the ENTER key toload the selected recipe.

Figure 5.22Shows the recipe load selection screen.

MAINMENU F1

CURRENT LOADED

######################################

SETTINGSMENU F2

SELECTRECIPE

TOLOAD

NEWRECIPELOADED

1- ######################################2- ######################################3- ######################################4- ######################################5- ######################################6- ######################################7- ######################################8- ######################################9- ######################################

10- ######################################11- ######################################12- ######################################

Operator Controls



Op. Interface > Settings Screen > Recipe Mang.

Recipe Save Selection ScreenThis screen is used to save the current machine settings under apreviously save recipe name. Use the UP and DOWN arrow keys toscroll through and select a previously save product recipe. Press theENTER key to save the current machine settings under the selectedproduct recipe name.

Figure 5.23Shows the recipe save selection screen.

MAINMENU F1

RECIPENAME F3

TO CHANGE RECIPE NAMESGOTO NAME EDIT SCREEN

SETTINGSMENU F2

SELECTRECIPE

TOSAVE

NEWRECIPESAVED

1- ######################################2- ######################################3- ######################################4- ######################################5- ######################################6- ######################################7- ######################################8- ######################################9- ######################################

10- ######################################11- ######################################12- ######################################

Operator Controls



Operator Interface

Alarms ScreenThe alarms screen appears whenever an alarm or warning conditionexists in the machine. Once the alarm or warning condition has beencorrected and the CLEAR ALARMS switch has been pressed, thealarm or warning message will be cleared.

Note: Alarm messages are conditions that prevent the bagmaker fromforming bags. Warning messages alert the operator toconditions that will eventually stop bag production.

Figure 5.24Shows the alarms screen.


7

4

1

8

5

2

9

6

3

. 0 -

F1 F2 F3 F4 F5

F6 F7 F8 F9 F10

CLEARALARMS

F1

SCALE NOT READYCARTONER NOT READYRE-CALC IN PROGRESSLOW FILM WARING

SCALE NOT READY

Operator Controls



SV Display

Mode Key

PV Display

Operator Interface

Temperature ControllersThe temperature controllers monitor and adjust the sealingtemperatures. There is one controller for each jaw assembly and onefor the seal band unit. The controller applies full voltage to the heatingcartridges until the set sealing temperature is reached. Then, it cutsthe power to the cartridges. While the temperature controller is on, ittoggles the power to the heating cartridges on and off to maintain thesealing temperature.

Each controller includes a PV display, an SV display, a MODE key,and two arrow keys. The PV display shows the current sealingtemperature. The SV display shows the desired sealing temperature.The arrow keys are used to set the sealing temperature and the alarmvalue.

Note: When the sealing temperature is out of the range set by thealarm value, the bagmaker stops bag forming and displays the�Out of Temperature� alarm message.

Figure 5.25Shows the temperature controllers.

Operator Controls



MAIN DISCONNECT SwitchThe MAIN DISCONNECT switch turns on or off all electrical power tothe bagmaker. Turn this switch to the ON position to connect power tothe bagmaker. Turn this switch to the OFF position to disconnectpower to the bagmaker.

Figure 5.26Shows the MAIN DISCONNECT switch.

Operator Controls



AIR DISCONNECT LeverThe AIR DISCONNECT lever controls the flow of air to the bagmaker.Move the lever to its vertical position to supply air to the machine.Move the lever to its horizontal position to stop the supply of air to themachine.

Figure 5.27Shows the AIR DISCONNECT lever in the closed position.

Operator Controls



Push-Buttons and Selector SwitchThe push-buttons and selector switch control the operating mode of thebagmaker. They include the SYSTEM READY lighted push-button, theJOG/AUTO selector switch, the JOG/RUN push-button, the STOP push-button, and the EMERGENCY STOP push-button.

SYSTEM READY Push-ButtonThis lighted push-button indicates the operating status of the machine.When the button is continuously lit, it indicates that the machine isready to run. When the button is flashing, it indicates that the machineneeds to perform a "reference run". When the button is not lit, itindicates that there is an active alarm present.

Figure 5.28.1Shows the SYSTEM READY push-button.

JOG/AUTO Selector SwitchThis two position selector switch determines the bagmaker operatingmode. When this switch is set to the JOG position, device jogging(film or jaw) is enabled. When this switch is set to AUTO, normal bagforming is enabled.

Figure 5.28.2Shows the JOG/AUTO selector switch.

Operator Controls



Push-Buttons and Selector Switch

JOG/RUN Push-ButtonThe JOG/RUN push-button runs the bagmaker in the selectedoperating mode. When the JOG/AUTO selector switch is set to JOG,press and hold the JOG/RUN push-button to jog the film drive or thejaw drive. When the JOG/AUTO selector switch is set to AUTO, pressand release the JOG/RUN button to start bag forming.

Figure 5.29.1Shows the JOG/RUN push-button.

STOP Push-ButtonThe STOP push-button ends bag production at the end of the formingcycle. Press this button once to stop the machine.

Figure 5.29.2Shows the STOP push-button.

Operator Controls



Push-Buttons and Selector Switch

EMERGENCY STOP Push-ButtonThe EMERGENCY STOP push-button immediately halts bagproduction without regard to the forming cycle. Press theEMERGENCY STOP button once to immediately halt the machine.This button should be pressed whenever there is perceived or actualdamage occurring to personnel or to the machine.

Figure 5.30Shows the EMERGENCY STOP push-button.

Machine Setup Procedures



Machine Setup ProceduresThis section describes procedures that can be used to prepare thebagmaker to form bags. These procedures include:

n Powering the Bagmakern Loading a Product Recipen Setting the Machine Speed and Bag Lengthn Installing the Forming Setn Loading a Film Rolln Threading a Film Rolln Vertical Seal Setupn Pneumatic Pressure Settingsn Setting the Film Tensionn Setting the Film Tracking Positionn Positioning the Automatic Film Tracking Sensorsn Registration Sensor Setup




AIR Lever

Powering the BagmakerTo power the bagmaker, you must activate the electrical and pneumaticsupplies.

To activate the electrical supply, turn the MAIN DISCONNECT switchto the ON position.

To activate the pneumatic supply, rotate the AIR DISCONNECT leverto the vertical position.

Figure 6.2Shows the MAIN DISCONNECT switch and the AIR DISCONNECT lever.




Loading a Product RecipeThe product recipe contains all of the forming parameters that thebagmaker needs to form bags. When the machine is first turned on,the last product recipe that was used on the machine is automaticallyloaded.

To load a different recipe:

1. From the operations screen, press the SETTINGS switch or F1 todisplay the settings screen.

2. From the settings screen, use the UP and DOWN arrow keys toselect the recipe management screen and then press ENTER toload the screen.

3. From the recipe management screen, press the LOAD switch orF3 to display the recipe load selection screen.

4. From the recipe load selection screen, use the UP and DOWNarrow keys to selected the desired product recipe and press theENTER key to load the recipe.

Figure 6.3Shows the load selection screen.


7

4

1

8

5

2

9

6

3

. 0 -

F1 F2 F3 F4 F5

F6 F7 F8 F9 F10

RETURN

MAINF1

RETURN

PREV.F2

RECIPE LOAD SELECTION

#1 = 130cu. in. 205mm FS#2 = 134cu. in. 205mm FS#3 = 148cu. in. 205mm FS#4 = 186cu. in. 205mm FS#5 = 226cu. in. 230mm FS#6 = 256cu. in. 255mm FS#7 = 330cu. in. 270mm FS#8 = 427cu. in. 315mm FS#9 = XXXcu. in. xxxmm FS




Setting the Machine Speed and Bag LengthThe bagmaker needs to know the machine operating speed and thebag length before it can form bags. When the bagmaker is first turnedon, it loads the machine speed and bag length settings from the lastproduction run. The following procedure describes how to set a differentmachine speed and bag length.

To change the length setting:

1. From the operations screen, press the LENGTH switch or F9 todisplay an input dialog box.

2. Use the numeric keypad to input the desired bag length setting inmillimeters then press the ENTER key to save your change.

To change the speed setting:

1. From the operations screen, press the SPEED switch or F8 todisplay an input dialog box.

2. Use the numeric keypad to input the desired speed setting in bagsper minute then press the ENTER key to save your change.

Figure 6.4Shows the main menu screen and the numeric keypad.


7

4

1

8

5

2

9

6

3

. 0 -

F1 F2 F3 F4 F5

F6 F7 F8 F9 F10

MOVE FILM

HEAT V. COOLING

SETTINGS

JOG SELECT

LENGTHF9

LEFTF6

RIGHTF7

FILMF10

MENU F1

ACT. POSITION

###

###

SPEEDF8

###

ENABLEF4

ENABLEF5

FEEDER BELTS

ENABLEF2

CLOSEDF3

50(Enter a value between 0 - 359)

Input DialogBox

ENTERKey




Installing the Forming SetEach bag style requires a different forming set. The forming set forthe desired bag style should be install before the film is threadedthrough the machine. This procedure describes how to install a formingset.

To install a forming set:

1. Choose the desired forming set. The number on the forming collarmount identifies the forming set.

2. Lift the forming set into the forming set mount.

Warning Forming sets can be very heavy. Use safe liftingtechniques when placing the forming set on its mount.

3. Tighten the forming set securing knobs to hold the forming set tothe machine frame.

Figure 6.5Shows the forming set installed on the machine frame.

SecuringKnob

Forming SetMount




Loading a Film RollOnce the forming set has been installed, the film roll can be loadedonto the film carriage.

To load a film roll:

1. Remove the film spindle form the film carriage.

2. Slide the spindle through a new roll of film.

3. Inflate the spindle so that it securely holds the film roll; inflate thespindle to 80-100 PSI.

4. Place the spindle on the film carriage as shown below.

Warning: Film rolls can be very heavy. Use safe lifting techniqueswhen placing the roll and spindle on the film carriage.

5. Once the roll and spindle are on the film carriage, deflate the spindleto free the roll.

6. Use a tape measure to center the film roll between the walls of thefilm carriage.

7. Once the roll is centered in the film carriage, inflate the spindle to80-100 PSI.

Figure 6.6Shows how to place a film roll on the film carriage.




Threading a Film RollAfter the film roll is loaded on the film carriage, it can be threadedthrough the bagmaker.

To thread the film:

1. Use the film routing label (located on the side of the bagmaker) topull the film through the film carriage and up to the forming collar.

2. Cut the film at a 45 degree angle.

3. Slide the pointed end of the film between the forming collar andthe forming tube.

4. Work the film around the forming collar and down the forming tube.

5. Use the setup rollers to adjust the angle of the film to match theangle of the forming collar.

Figure 6.7Shows the steps used to thread film.

2 3

4 5




Vertical Seal SetupThe vertical sealing device must be positioned relative to the formingtube before it can create vertical seals. Setting up the vertical sealingdevice consists of moving it within striking distance of the formingtube and centering the vertical sealing band on the desired sealinglocation.

The stroke of the vertical engage/retract device is 20mm. In order forthe vertical sealing device to produce adequate sealing pressure, thevertical sealing band must be 18mm away from the forming tube whenthe vertical sealing device is in the retracted position.

The position of the vertical sealing device can be adjusted laterally toaccommodate different forming sets. When positioning the verticalsealing device laterally, the vertical sealing band must be centeredover the silicon strip in the forming tube.




Vertical Seal SetupTo position the device:

1. Loosen the position locking levers.

2. Slide the vertical sealing device towards the forming tube until thesealing band is 18 millimeters away from the forming tube in theretracted position.

3. Use the positioning scales to ensure that both sides of the deviceare the same distance from the tube.

4. Tighten the locking levers.

5. Loosen the lateral adjustment bolts.

6. Slide the vertical sealing device until the vertical sealing band iscentered on the silicon strip embedded in the forming tube

7. Tighten the lateral adjustment bolts.

Figure 6.9Shows the vertical sealing device and its positioning devices.

PositionLocking Lever

LateralAdjustment Bolts

PositioningScale




Pneumatic Pressure SettingsThe pressure settings for the engage/retract devices and the coolingdevices will depend on the production environment. Ambienttemperature, component wear, and other factors effect the pressuresettings for these devices. However, as a starting point, set thepressure for the vertical seal engage/retract device, the beltassemblies, and the horizontal cooling device to approximately 32PSI. The vertical cooling device does not have a pressure gaugebecause the pressure setting is important but not critical. When settingthe vertical cooling pressure, start by turning the flow control valve toits medium position.

Figure 6.10Shows the pneumatic pressure regulators.

Horizontal CoolingPressure

Belt Pressure

VerticalCooling

Vertical SealingPressure




Setting the Film TensionProper film tension prevents slack from forming in the film web. Whenthe film web losses tension, the film moves away form the registrationsensor or shifts around the forming collar. Before setting the filmtension, you must setup the dancer assembly to produce nominal filmtension.

To setup the dancer assembly to produce nominal film tension:

1. Push the dancer arms to the bottom of the film carriage.

2. Adjust the upper spring tensioner so that it just touches the top ofthe upper spring.

3. Pull the dancer arms to the top of the film carriage.

4. Adjust the lower spring tensioner so that it just touches the bottomof the lower spring.

The setup above will produce nominal film tension. From this point,the film tension should be set high enough to prevent slack from formingin the film web yet as low as possible to reduce the strain on the filmfeeding device.

To increase the film tension, turn both spring tensioners so that theycompress the springs. To decrease the film tension, turn both springtensioners so that they relieve pressure on the springs.

Figure 6.11Shows the dancer assembly.

Dancer Arm

Upper SpringTensioner

Lower SpringTensioner




Setting the Film Tracking PositionFilm tracking controls the alignment of the vertical seal. You will wantto set the film tracking position so that the edges of the film tube areeven with one another or so that the outer edge slightly overlaps theinner edge. The process of setting the film tracking position is alsoreferred to as �establishing a film tracking path�.

To establish a film tracking path:

1. Start the bagmaker and allow it to form bags.

Note: At this point, it is not important whether or not thehorizontal and vertical seals are forming correctly; onlythat you can see how the edges of the film tube arealigned.

2. While the bagmaker is running, use the MOVE FILM CARRIAGEswitch on the main menu screen to adjust the position of the filmweb. Adjust the film tracking until the edges of the film tube areeven or until the outer edge slightly overlaps the inner edge.

Figure 6.12Shows how to align the edges of the film tube.

Inside of Forming Tube

Outer Edge

Inner Edge




Film Web

Outer Senosr

Inner Sensor

Positioning the Automatic Film Tracking SensorsAutomatic film tracking automatically keeps the edges of the film tubeeven. In order for automatic film tracking to work effectively, theautomatic film tracking sensors must be positioned relative to the filmweb after the film tracking path has been established.

This procedure describes how to position the automatic film trackingsensors relative to the position of the film web. At this point, the filmtracking path should have been established.

To position the sensors, use the adjustment knob to move the sensorsso that the inner sensor is blocked by the film web and the outersensor is not blocked by the film web.

Note: Each sensor is equipped with a status LED (mounted on thefilm carriage frame or inside of the electrical cabinet).

Figure 6.13Shows how to position the automatic film tracking sensors.




Registration Sensor SetupThe registration sensor must be setup according to the film type. Ifthe bagmaker is using nonregistered film, the sensor must be disableor it will cause registration errors. If the bagmaker is using registeredfilm, the sensor must be positioned relative to the registration marks,enabled, and the photoeye window and photoeye correction valuesmust be set.

Figure 6.14Shows a piece of registered film and a piece of nonregistered film.

Net Wt. 12 oz

Net Wt. 12 oz

Registration Mark

Artwork

Non-Registered FilmRegistered Film




Registration Sensor Setup

Sensor Setup for Non-Registered FilmIf the bagmaker is using nonregistered film, the only setup task thatneeds to be performed is to disable the sensor.

To disable the registration sensor:

1. From the operations screen, press the SETTINGS menu switchto display the settings menu screen.

2. From the settings menu screen, press the PHOTOEYE switch todisplay the photoeye screen.

3. From the photoeye screen, set the ENABLE/DISABLE switch toDISABLE.

Figure 6.15Shows the photoeye screen.

DISABLEDF6SWITCH

###OFFSET IN(mm) F8

###WINDOW IN(mm) F7

PHOTOEYE




Registration Sensor Setup

Sensor Setup for Registered FilmWhen the bagmaker is using registered film, the registration sensormust be positioned relative to the registration marks, enabled, andthe photoeye window and photoeye correction values must be set.

To position the sensor:

1. Loosen the position adjustment lever.

2. Slide the sensor until its lens is in the path of the registration marks.

3. Tighten the position adjustment lever.

To enable the sensor:

1. From the main menu screen, press the SETTINGS menu switchto display the settings menu screen.

2. From the settings menu screen, press the PHOTOEYE switch todisplay the photoeye screen.

3. From the photoeye screen, set the ENABLE/DISABLE switch toENABLE.

Figure 6.16Shows the photoeye screen and the registration sensor.

PositionAdj. Lever Sensor

LensPHOTOEYE

ENABLEF6

SWITCH

###OFFSET IN(mm) F8

###WINDOW IN(mm) F7




Sensor Setup for Registered Film

Photoeye Window and Photoeye Correction SettingsThe values for the photoeye window and photoeye correction settingswill depend on the film layout. The photoeye window setting tells thebagmaker when to look for the registration marks. If there is artworkprinted in the registration field that could generate false signals, thephotoeye window setting can prevent the bagmaker from examiningthe signal until the artwork has passed.

The photoeye correction setting offsets the cutting and sealing location.It makes the bagmaker feed more film so that the desired sealinglocation is centered on the sealing jaws.

The following procedures describe how to determine the values forthe photoeye window and the photoeye correction settings.





Determining the Photoeye Window ValueIf there is no artwork printed in the registration field, set the photoeyewindow setting to zero (0). This allows the bagmaker to continuallylook for the registration marks.

If there is artwork printed in the registration field, set the photoeyewindow setting to 1/2 the distance between the artwork and theregistration mark. This will prevent the bagmaker from looking for amark until just before the expected position of a mark.

Figure 6.18Shows how to determine the photoeye window setting.

Net Wt. 12 oz

Net Wt. 12 oz

Registration Field

PhotoeyeWindow





Determining the Photoeye Correction ValueTo determine the photoeye correction value, you must create a fewempty bags so that you can see where the bagmaker is creating thehorizontal seals. Then, you must determine how much additional filmneeds to be advanced to position the seal in the desired location.

To determine the photoeye correction value:

1. Disable the product feeder. You do not want product drops duringthis procedure.

2. Disable the cutting knife. You want the bagmaker to produce astring of bags so that you can see how the sealing position needsto change.

3. Start the bagmaker and allow it to form five or six empty bags.

4. Measure the distance between the desired and actual cut locations.

5. Enter this measurement (in millimeters) as the photoeye correctionvalue.

Figure 6.19Shows how to determine the photoeye correction value.

Net Wt. 12 oz

Net Wt. 12 oz

Net Wt. 12 oz

Actual CutLocation

Desired CutLocation Photoeye

Correction

Operating Procedures



Operating ProceduresThis section describes procedures that may be used on a daily basiswhen operating the bagmaker. It describes how to:

n Start a Production Runn Shut Down the Bagmakern Restart the Bagmaker after and E-Stopn Jog the Bagmaker




Start-UpUse the following procedures to start-up the bagmaker. At this point,the forming collar should be installed in the machine and the film shouldbe loaded and thread down past the film transport belts.

The start-up procedures are:

n Preparing the Bagmakern Making Empty Bagsn Checking Empty Bagsn Making Filled Bagsn Check Filled Bagsn Starting Production




Preparing the BagmakerUse the following procedure to prepare the bagmaker to form emptybags.

To prepare the bagmaker to form empty bags:

1. Check that the machine is powered up. If it is not, refer to section6-0, Machine Setup Procedures.

2. Check that the desired product recipe is loaded. If it is not, refer tosection 6-0, Machine Setup Procedures.

3. Check that the desired bag length and machine speed are set. Ifthey are not, refer to section 6-0, Machine Setup Procedures.

4. From the operations screen, set the HEAT switch to ENABLED toallow the sealing devices to heat.

5. From the operations screen, set the FEEDER switch to DISABLEDto prevent product drops during empty bag production.

6. Check that the sealing temperature for all sealing devices is correctfor the film type.

7. Check that there are no active warnings or alarms.




Making Empty BagsEmpty bag production will indicate whether adjustments need to bemade to the sealing devices, to the film tracking, to film feeding, or tofilm registration (if using registered film).

Use the following procedure to make empty bags:

1. Set the JOG/AUTO selector switch to AUTO.

2. Press the SYSTEM READY push-button.

If the button does not stay lit, there is an alarm condition present.Correct the alarm condition, clear the alarm from the screen, andpress the SYSTEM READY push-button again.

3. Press the JOG/RUN push-button to begin empty bag production.

4. Allow the bagmaker to form a few empty bags.

5. Press the STOP push-button to stop empty bag production.




Checking Empty BagsUse the following procedure to check the empty bags:

1. Squeeze the bags to check the integrity of the seals.

If the seals leak air, check the sealing temperature.

2. Check that the edges of the vertical seal are even.

If the edges of the vertical seal are not even:

a. Adjust the film tracking (left or right).

b. Check that the film moves over the forming collar smoothly.

3. Check that the bags are cut to the desired length.

If the bags are not cut to the desired length:

a. Check the bag length setting on the operations screen.

b. If using registered film, check the settings on the photoeyescreen.

c. Check the film tension.

d. Check that the belts are not slipping on the film.

4. If gusseting was used, check that they are even; the bags shouldlook symmetric.




Making Filled BagsOnce the bagmaker is producing empty bags, it is ready to producefilled bags. Filled bag production will indicate whether adjustmentsneed to be made to the product drop timing or product drop quantity.

Use the following procedure to make filled bags:

1. From the operations screen, set the FEEDER switch to ENABLEDto allow product drops.

2. Set the JOG/AUTO selector switch to the AUTO position.


If the button does not stay lit, there is an alarm condition present.Correct the alarm condition, clear the alarm from the screen, andpress the SYSTEM READY push-button again

4. Press the JOG/RUN push-button to begin filled bag production.

5. Allow the bagmaker to form a few filled bags.

6. Press the STOP push-button to stop filled bag production.




Checking Filled BagsUse the following procedure to check the quality of the filled bags:

1. Check the amount of product in the bags.

If the bags do not have the correct amount of product in them,check the product feeder.

2. Check that there is no product trapped in the horizontal seals.

If there is product trapped in the seals, adjust the product droptiming.

3. Check that the desired amount of air is trapped in the bag.

If there is too little or too much air in the bags, adjust the positionof the foam deflators.




Starting a Production RunOnce the bagmaker is producing quality filled bags, start the normalproduction run.

To start the normal production run:

1. Set the JOG/AUTO selector switch to the AUTO position.



3. Press the JOG/RUN push-button to begin normal filled bagproduction.




Shut Down the BagmakerUse the following procedures to stop or shut down the bagmaker innormal and emergency situations.

Emergency StopPress the EMERGENCY STOP push-button to stop the bagmaker inan emergency situation.

Normal StopPress the STOP push-button to halt the bagmaker under normalconditions.

Extended ShutdownUse the following procedure to shut down the bagmaker for extendedperiods of time.

1. Press the STOP push-button to halt bag production.

2. Turn the MAIN DISCONNECT switch to the OFF position.

3. Raise the AIR DISCONNECT lever to shut off the air supply to themachine.

4. Clean the machine by following the maintenance procedure outlinein section 10-0, Maintenance Procedures.




Restart the Bagmaker After an E-StopUse the following procedure to restart the bagmaker after anEMERGENCY STOP.

1. Use the alarms screen to help resolve the problems that causedthe emergency stop.

2. Pull out the EMERGENCY STOP push-button.



4. Press the JOG/RUN push-button to resume bag production.




Jog the BagmakerJogging the bagmaker means to operate it at a slow steady pace.Both the film feeding device and the horizontal sealing device can bejogged independent of one another. Use film feed jogging to advancefilm down the forming tube. Use jaw jogging to open or close thesealing jaws.

Film Feed JoggingUse the following procedure to jog the film feeding device.

To jog the film feeding device:

1. From the operations screen, set the JOG SELECT switch to FILMJOGGING.

2. From the bagmaker control panel, set the JOG/AUTO selectorswitch to JOG.

3. Press and hold the JOG/RUN push-button to jog the film feedingdevice. When the JOG/RUN push-button is released, the filmfeeding device will stop.

Jaw JoggingUse the following procedure to jog the horizontal sealing jaws.

To jog the horizontal sealing device:

1. From the operations screen, set the JOG SELECT switch to JAWSFORWARD or JAWS REVERSE.

2. From the bagmaker control panel, set the JOG/AUTO selectorswitch to JOG.

3. Press and hold the JOG/RUN push-button to jog the horizontalsealing device. When the JOG/RUN push-button is released, thehorizontal sealing device will stop.

Working with Components



Working with ComponentsThis section describes procedures that can be used to replace orrealign components. These procedures include:

n Replacing Heater Cartridges and Temperature Probesn Replacing the Feeding Beltsn Replacing the Cutting Knifen Aligning the Forming Collarn Aligning the Film Feed Belt Assemblies




Replacing Heater Cartridges and Temp. ProbesThis section describes how to replace the heating cartridges and thetemperature probes in the horizontal sealing jaws and in the verticalsealing band unit.

Horizontal sealing JawsAt some point, the heating cartridges and the temperature probesinside of the horizontal sealing jaws must be replaced. Use thefollowing procedure to replace the heating cartridges and thetemperature probe in the front jaw assembly. The same procedurecan be applied to replace the heating cartridges and the temperatureprobe in the rear jaw assembly. Before starting this procedure, makesure that the bagmaker is locked-out and that the sealing jaws havecooled.

Note: It is not necessary to remove the c-frames from the machine toperform this procedure. They have been removed in theillustrations for clarity.

To replace the heater cartridges and the temperature probes:

1. Push the knife extender inward to extend the cutting knife.

2. Locate the knife securing screw under the front jaw body.

3. Loosen the screw until the slotted knife can be removed from betweenthe jaws.

4. Use a pair of pliers to remove the knife blade.

Figure 8.2Shows the knife extender.

KnifeExtender

Hex HeadBolt Cap Screw




Replacing Heater Cartridges and Temp Probes

Horizontal sealing Jaws5. Remove the two hex head bolts that secure the knife assembly to

the c-frame.

6. Remove the two socket head cap screws that hold the jaw carrierin the c-frame.

Figure 8.3.1Shows the bolts and screws to remove to free the front jaw body.

7. Remove the knife air cylinder from the c-frame.

8. Remove the jaw body and its carrier from the c-frame.

C-Frame

Jaw CarrierJaw Body

KnifeExtender

Hex HeadBolt Cap Screw

Figure 8.3.2Shows how to remove the jaw body and its jaw carrier from the c-frame.





Horizontal sealing Jaws9. Remove the terminal housing from the jaw body.

10.Remove the terminal housing cover to expose the ceramicconnectors.

11.Disconnect the heating cartridges and the temperature probe fromthe ceramic connectors.

12.Remove the heating cartridges and the temperature probe fromthe jaw body.

13. Install the new heating cartridges and the new temperature probein the jaw body.

14.Connect the heating cartridges and the temperature probe to theceramic connectors.

15.Assemble and install the front jaw assembly into its c-frame.

TemperatureProbe

CeramicConnector

HeatingCartridge

TerminalHousing

Figure 8.4Shows the terminal housing and the ceramic connectors.





Vertical Sealing DeviceAt some point, the heating cartridges and the temperature probe insideof the seal band unit must be replaced. Use the following procedureto replace these items. Before starting this procedure, make sure thatthe bagmaker is locked-out and that the seal band unit has cooled.

To replace the heating cartridges and the temperature probe:

1. Remove the seal band drive unit from the heating bar assembly byremoving the two hex head bolts that secure it to the assembly.

Note: The seal band drive unit is heavy. Use two people to removethe unit from the machine.

2. Remove the terminal housing from the heating bar assembly toexpose the ceramic connectors.

Figure 8.5Shows how to remove the seal band drive unit from the heating bar assem-bly.

Heating BarAssembly

Hex HeadBolt

Seal BandDrive Unit

TerminalHousing





Vertical Sealing Device3. Disconnect the heating cartridges and the temperature probe from

the ceramic connectors.

4. Remove the heating cartridges and the temperature probe formthe heating bar assembly.

5. Install the new heating cartridges and the temperature probe inthe heating bar assembly.

6. Install the terminal housing on the heating bar assembly.

7. Mount the seal band drive unit to the heating bar assembly.

Figure 8.6Shows the heating bar assembly.

Heating Bar

HeatingCartridge

CeramicConnector




Replacing the Film Feed BeltsOver time, the film feed belts will begin to loose traction against the filmbecause of wear. At that point, it is time to replace the belts. Use thefollowing procedure to replace them. Before starting this procedure,make sure that the bagmaker is locked-out.

To replace a film feed belt:

1. Loosen the securing nut that holds the upper belt pulley in place.

2. Loosen the belt tensioner until there is enough slack in the belt toremove it from around the belt pulleys.

3. Install the new belt.

4. Tension the belt using the belt tensioner.

5. Tighten the securing nut that holds the upper belt pulley in place.

Note: Always replace both belts at the same time.

Figure 8.7Shows how to replace a film feed belt.

BeltTensioner

SecuringBolt




Replacing the Cutting KnifeWhen the cutting knife consistently fails to produce a crisp cut it is timeto replace it. Use the following procedure to replace the knife. Beforestarting this procedure, make sure that the bagmaker is locked-out.

To replace the knife:

1. Check that the jaws are at the bottom of their stroke.

2. Push the knife extender inward to extend the knife.

3. Locate the knife securing screw under the front jaw body.

4. Loosen the screw until the slotted knife can be removed from betweenthe jaws.

Warning: Use a pair of pliers to remove the knife. Even though it isdull, it can easily cut you.

5. Insert the new knife into the knife assembly.

Warning: Use a pair of pliers to install the new knife. New knivesare extremely shape.

6. Tighten the knife securing screw.

Figure 8.8Shows the knife assembly.

KnifeExtender




Aligning the Forming SetForming set alignment is critical to bag forming. If the forming set is notproperly aligned, the vertical seal may not form or the bags may appeartwisted. The forming set alignment positions the forming tube so that itis square with the machine frame and so that there is equal clearancebetween the forming tube and the forming collar on all sides.

To align the forming tube to the machine frame, adjust the height of thestandoffs so that the forming tube is square with the machine frame.

To align the forming collar to the forming tube, loosen the forming collarsecuring bolts and slide the collar until there is equal clearance (on allsides) between the forming collar and the forming tube.

Figure 8.7Shows the forming set standoffs and the forming collar securing bolts.

Securing Bolt

Stand-Off




Aligning the Belt AssembliesWhenever the belt assemblies are removed from their drive shafts, theymust be aligned to the flat surfaces on the forming tube when they arereinstalled. The following procedure describes how to align the beltassemblies to the forming tube.

To align a belt assembly to the forming tube:

1. Loosen the collar bolt on the belt assembly.

2. Rotate the assembly away from the tube and then back to the tubeuntil it is flush with the flat surface on the side of the forming tube;let the forming tube align the belt assembly.

3. Tighten the collar bolt.

Figure 8.8Shows how to align a belt assembly to the forming tube.

Collar Bolt

Changeover Procedure



Changeover ProcedureThis procedure describes how to changeover the bagmaker to form adifferent bag style.

To changeover the bagmaker:

1. Remove the existing forming set.

2. Install the appropriate forming set.

3. If the bag style you want to form requires a different vertical sealingdevice, remove the existing vertical sealing device and install theappropriate vertical sealing device.

4. Follow the procedures outlined in section 6.0, Machine SetupProcedures to prepare the bagmaker to form bags.

Maintenance Procedures



Maintenance ProceduresThe following procedures describe how to clean and maintain thebagmaker. The scheduling of the procedures is based on the bagmakerrunning one shift per day (hours per shift). If the bagmaker is operatingfor more or fewer shifts, adjust the cleaning and maintenance schedulesaccordingly.

Note: Before performing any cleaning or maintenance procedures,ensure that the bagmaker is locked-out. See section 2-0, SafetyInstructions.




Daily CleaningEach day, use the following procedure to clean the bagmaker.

1. Use an appropriate cleaning agent to clean any food contactsurfaces. If necessary, contact the Rovema Service Departmentto identify an appropriate cleaning agent for your specificapplication.

2. Use a mild household cleanser and a moist cloth to clean thehousing.

3. Clean the touchscreen display with a moist cloth only.

4. Vacuum or sweep product and film waste from the bagmaker.

5. Use a brass bristle brush to clean the film residue from thehorizontal sealing jaws and from the seal band.




Daily MaintenanceEach day, use the following procedure to maintain the bagmaker.

1. Check that the guard door switches and the EMERGENCY STOPswitch is working properly.

2. Remove any condensed water from the air filter/regulator bowl.

3. Inspect transport belts for wear

4. Check the vacuum filter.




Weekly MaintenanceEach week, use the following procedure to maintain the bagmaker.

1. Remove the jaw drive covers and inspect the timing belts for wearand proper tensioning.

2. Check that all of the film guide rollers are moving freely.

3. Inspect the Teflon tape on the forming tube.

4. Check that the guard door switches and the EMERGENCY STOPswitch are working properly.

Figure 10.1Shows the jaw drive timing belts.

Troubleshooting Guide



POSSIBLE CAUSE1) The E-STOP push-button is

depressed.2) The E-STOP push-button is defective.3) Missing 24 VDC power supply.

CORRECTIVE ACTION1) Reset the E-STOP push-button.2) Check the button's contacts.3) Check for a 24 VDC supply at the

contacts.

EMERGENCY STOP PUSH-BUTTON

SAFETY CIRCUIT LATCH

POSSIBLE CAUSE1) The front guard door is open.2) The guard door limit switch is

defective.3) The bagmaker is not ready.

CORRECTIVE ACTION1) Close the guard door.2) Check the switch's contacts3) Press the SYSTEM READY push-

button.

LOW AIR PRESSURE

POSSIBLE CAUSE1) The air supply has been cutoff or

decreased.2) The air pressure monitor is defective.

CORRECTIVE ACTION1) Turn on the air supply. Set to 85 psi.2) Check the air pressure switch.

REVERSE MODEPOSSIBLE CAUSE1) The bagger is set to the JAWS REV

jogging mode.2) The jaw jam logic was activated.

CORRECTIVE ACTION1) Set the JOG/AUTO switch to AUTO.2) Clear the jam and press the ALARM

RESET on the main menu screen.

BELTS OPEN

POSSIBLE CAUSE1) The BELTS OPEN/CLOSE cell is set to

OPEN.

CORRECTIVE ACTION1) Set to CLOSE.

Troubleshooting GuideThis chapter contains a list of fault messages, their possible cause(s), and correctiveactions that may resolve them.




FILM SPLICE TABLE ACTIVATED

POSSIBLE CAUSE1) The out of film sensor has triggered

the splice table to clamp the film end.

JOGGING MODE

POSSIBLE CAUSE1) The JOG/AUTO selector switch is set

to JOG.

CORRECTIVE ACTION1) Set the selector switch to AUTO.

TEMPERATURE OUT OF RANGE

POSSIBLE CAUSE1) The temperature controller is not

turned on.2) The temperature controller ALM1 value

is to small.3) The RTD is bad.4) The heating element is bad.

CORRECTIVE ACTION1) Set the JAW HEAT ENABLE cell to

ENABLE.2) Increase the ALM1 value.3) Check the RTD.4) Check the heating element.

REGISTRATION FAILED

POSSIBLE CAUSE1) The film registration photoeye is not

aligned with the registration marks onthe film.

2) The sensitive of the photoeye is setincorrectly.

3) The film is shiny and reflects thesensor light source away from thesensor�s lens.

CORRECTIVE ACTION1) Check that the lens of the photoeye is

in the path of the registration marks.

2) Adjust the sensitivity of the photoeye.Refer to the photoeye specificationsheet in the Electrical Documentation.

3) Angle the sensor 10 to 15 degrees.

FILM CARRIAGE LEFT LIMIT

POSSIBLE CAUSE1) The film carriage has traveled to its

maximum left limit.

CORRECTIVE ACTION1) Use the MOVE FILM CARRIAGE cell

to move the carriage towards thecenter.

CORRECTIVE ACTION1) Press the FILM UNCLAMP push-button.




SCALE NOT READY/FEEDER NOT READY

POSSIBLE CAUSE1) The SCALE or FEEDER ENABLE

switch is set to ENABLE but the scaleor feeder has not sent its ready signal.

CORRECTIVE ACTION1) Set the switch to "DISABLE".2) Wait for the scale or feeder to send a

ready signal.3) Troubleshoot the scale.

PREMIUM FEEDER NOT READYPOSSIBLE CAUSE1) The PREMIUM/COUPON cell is set to

ENABLE.

CORRECTIVE ACTION1) Set the PREMIUM/COUPON cell to

DISABLE.2) Troubleshoot the Premium feeder.

MOTION CONTROLLER RE-CALC IN PROGRESS

POSSIBLE CAUSE1) Program parameters have been

changed and the bagmaker isrecalculating the horizontal setupparameters.

CORRECTIVE ACTION1) Wait for the bagmaker to finish

recalculating.

OUT OF FILM

POSSIBLE CAUSE1) The film roll is exhausted.2) The end of the film is taped to the film

core.3) The power unwind motor is not

unwinding film.4) The dancer assembly brake is not

properly set.

CORRECTIVE ACTION1) Replace the film roll.2) Cut the film from the core and replace

the film roll.3) Check the power unwind motor and the

unwind stop sensor.4) Adjust the dancer brake pressure.

INVALID CALCULATION

POSSIBLE CAUSE1) A program parameter value is out of

range; too small or too large.

CORRECTIVE ACTION1) Enter a value within the acceptable

range.

FILM CARRIAGE RIGHT LIMIT

POSSIBLE CAUSE1) The film carriage has traveled to its

maximum right limit.

CORRECTIVE ACTION1) Use the MOVE FILM CARRIAGE cell

to move the carriage towards thecenter.




MOTION CONTROLLER AND SERVO AXIS MODULE ERROR MESSAGES

ERROR MESSAGEJaw Resolver LossFilm Resolver LossJaw Axis Module HDWR FaultSystem Module HDWR FaultAxis Power FaultAxis Bus LossJaw Axis Motor Overtemp FaultFilm Axis Motor Overtemp FaultJaw Axis Drive Overtemp FaultFilm Axis Drive Overtemp FaultJaw Axis FaultFilm Axis FaultSystem Bus Overvoltage FaultSystem Bus Under voltage FaultSystem Overtemp FaultSystem control Power FaultSystem Phase Lose FaultSystem Ground Fault

CORRECTIVE ACTIONRefer to the 1394 Controller User Manualto resolve motion controller and axismodule errors.

VERTICAL SEAL DRIVE ERROR MESSAGES

ERROR MESSAGEVertical Seal Drive FaultVertical Seal Motor Overload

CORRECTIVE ACTIONRefer to the 160 SSC Controller UserManual to resolve vertical seal driveerrors.

POWER UNWIND ERROR MESSAGES

ERROR MESSAGEPower Unwind Drive FaultPower Unwind Motor Overload

CORRECTIVE ACTIONRefer to the 160 SSC Controller UserManual to resolve power unwind errors.

Documents

VPK Operations Manual