CAUTION Read carefully all the instructions of this manual before start any operation on this machine. Do not put your hands close to any moving part of the machine. Do not make any adjustment when the machine is running. Make sure to turn the power source off if any major mechanical adjustment is practiced to the machine. Make a full check of the machine previous to start. Adjust and tight the possible loosen parts found on the machine. Do not aloud any children close to the machine. All visitors should keep a safety distance from the machine. Do not put your hands near the warm surfaces of the shrinking tunnel. Wear proper protection goggles to operate this machine. It is necessary to have easy available security equipment. Machine: Model: SHRINK LABEL AUTOMATIC APLICATOR SLEEVEPRO 450AB Input Voltage: Contact: 400 VAC, 3PH, 50Hz Karlville Development (U.S.A) Inc. 1111 Brickell Bay Dr Suite 512 Miami FL 33131 Web site: www.karlville.com Phone Number: +1(305)533-1051 Fax Number: +1(305)533-1055 KARLVILLE DEVELOPMENT LLC 1 REV SM2-007
WARRANTY All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, mechanical, photocopying, recording, or otherwise, without the prior written permission of KARLVILLE DEVELOPMENT LLC. No patent liability is assumed with respect to the use of the information contained herein. While every precaution has been taken in the preparation of this tool, KARLVILLE DEVELOPMENT LLC assumes no responsibility for errors or omissions. Neither is any liability assumed for damages resulting from the use of the information contained herein. COPYRIGHT 2002 KARLVILLE DEVELOPMENT LLC., FL, US KARLVILLE DEVELOPMENT LLC 2 REV SM2-007
CONTENTS 1. DESCRIPTIONS AND FUNCTIONS... 5 A. LOWER CABINET...5 B. SLEEVE FEEDING GROUP...5 a) Unwinder...5 b) Tension Control Device...5 c) Rotation Device Option...6 d) Driving Device...6 C. SLIP-ON DEVICE...7 D. HOLDER...7 E. CUTTER...7 F. CONTAINER FEEDING SCREW...8 G. POSITION CONTROL GROUP...8 a) Holding Device...8 b) Label Forcing Devices...8 c) Clapping Device Options...10 H. CONVEYOR...10 I. SHRINK TUNNEL...10 a) Main Structure...10 J. PREHEATING DEVICE OPTION...10 2. MAIN CONTROL PANEL...12 3. INSTALLATION...13 A. Installation instructions...13 a) Unpacking the machine:...13 b) Fittings...13 c) Leveling the machine...13 d) Power Requirements...13 4. TOUCH SCREEN OPERATING INSTRUCTIONS...16 5. OPERATION...35 Automatic Operation Description...35 Sensitivity Adjustment...37 6. OPERATING PROCEDURE...39 7. APPENDIX...41 A. Shrink Tunnel Operation Procedure...41 B. Procedure to Replace the Razor Blades on the Cutting System...42 C. Lubrication...43 D. Trouble Shooting...43 KARLVILLE DEVELOPMENT LLC 3 REV SM2-007
Sleeve Jammed On the Holder...43 Sleeve Cutting Off Incompletely and/or Uneven Cutting Surface...44 Incorrect Cutting/Perforation Position...44 Adjust the position of the Cutting/Perforation system....44 Poor Shrinking Performance of the Shrunk Sleeve...44 The container fall down after the application...44 The Slip-On Rollers cannot shoot the sleeve accurately on the container...44 E. Machine Threading Drawing 45 KARLVILLE DEVELOPMENT LLC 4 REV SM2-007
1. DESCRIPTIONS AND FUNCTIONS A. LOWER CABINET The front section of the lower cabinet can be used as a storage cabinet for the customer to store tools, Holders, parts of the machine, etc. The electric-electronic control panel is on the rear side of the machine, no tools or parts can be stored in this panel. There are four removable legs under the lower cabinet. These legs are height-adjustable and should be used to level the machine and adjust the conveyor s height. The range of the conveyor s height is 850 mm to 1000 mm without the legs and from 1050 mm to 1200 mm with the removable legs. Conveyor Storage Front Doors Control Panel Removable Legs Removable Legs B. SLEEVE FEEDING GROUP a) Unwinder The diameter of the unwind holder is adjustable from 5 inches to 10 inches. There are four shafts in the unwind holder to secure the rolls. To adjust the diameter, rotate synchronously the pulley and the four shafts. b) Tension Control Device The Proximity Sensor, the Sleeve Feeding Device, the Linear Motion Guide, and the Supporting Rollers offer an excellent tension control for sleeve feeding performance. To adjust the unwind tension on the sleeve, the adjusting nut on the rear of every unwind shaft should be tighten (to increase the tension) or loosen to (decrease the tension). KARLVILLE DEVELOPMENT LLC 5 REV SM2-007
Sleeve Feeding Unit Idler Rollers Supporting Roller Motor Driven Roller Holding Shafts Sliding Guide Unwind Unit Fig. 2 Proximity Switch Unwind & Feeding Units c) Rotation Device Option The Rotation Device is only for square shaped container. The device uses four extra rollers to change the sleeve direction to 45 degree and then slip the sleeve on to the bottle. In addition to the Rotation Device, the Sleeve Pro Machine still needs a special 45 degree Holder for square shaped containers application. d) Driving Device The Driving Device is made from anodized aluminum. There are two Supporting Rollers and two Driving Rollers in Driving Device to hold the Holder. The device is adjustable to fit the diameter of Holder from 25 mm to 155 mm. It is very easy to adjust. Only rotate one knob to move all rollers of the device synchronous. The Driving Rollers are controlled by MITSUBISHI Servo Motor and a Sleeve Position Detecting Sensor; their function is to drive the sleeve on the Holder through cutter into the correct position for cutting. KARLVILLE DEVELOPMENT LLC 6 REV SM2-007
C. SLIP-ON DEVICE The Slip-On Device system is made from anodized aluminum. There are two driving rollers, Slip-On Rollers, in the device to drive the cut sleeve from Holder on the container. The Slip-On Rollers are controlled by one fixed speed motor. The Slip-On Device is adjustable. There are two knobs in the device. One knob is adjusting the interval of two Slip-On Rollers to fit the diameter range of Holder from 25 mm to 155 mm. Another knob is adjusting the interval between the Slip-On Roller and the Cutter to fit the range of sleeve cutting length from 20 mm to 250 mm. D. HOLDER The Holder is made from anodized aluminum or hard plastic. Different size Holders are necessary for different bottle diameters or different sleeve length. E. CUTTER The Cutting device is made from anodized aluminum. There are four sizes for the cutting device with their respective diameter ranges. Within the diameter range, each Cutter is easy to adjust for different sleeve diameters. The size range of the Cutters is as follows: Size A. Diameter from 25 mm to 60 mm Size B. Diameter from 50 mm to 98 mm Size C. Diameter from 90 mm to 125 mm Size D. Diameter from 115 mm to 155 mm KARLVILLE DEVELOPMENT LLC 7 REV SM2-007
F. CONTAINER FEEDING SCREW The function of the Container Feeding Screw is feeding the containers into the label shooting system with a specific constant separation in between. The separation also depends of the combination of the container feeding screw s speed and the conveyor s speed The Bottle Feeding Screw is made from hard plastic and driven by one 1/4 HP Gear Motor which is controlled by one 1/2 HP Inverter. Container Feeding Screw G. POSITION CONTROL GROUP a) Holding Device This device holds the label in the desired position on the container. This device has two V-type belts, an adjustable height position system and a distance between belts adjusting system. There are two knobs for adjusting the Holding Device. One knob on the front of the device adjusts the distance between two V belts from 40mm to 120mm. The other knob adjusts the height between conveyor and V Belts from 15mm to 200mm. b) Label Forcing Devices This system forces the label to go all the way on the container until it is stopped by the V belts. The two Forcing Devices are driven by one 25 watts motor each, the motors drive two rotational rubber brushes to force the sleeve into the required position. KARLVILLE DEVELOPMENT LLC 8 REV SM2-007
Label Positioning System, Top View Label Positioning System, Front View KARLVILLE DEVELOPMENT LLC 9 REV SM2-007
c) Clapping Device Options According to some conditions that the Holding Device and Forcing Device cannot control the sleeve application accurately; for these applications, the optional Clapping Device must be used to secure the label on the container. These are some examples of these applications: Cone Shaped Containers: when the diameter of the sleeve is much bigger than the diameter of the slip-on level of the bottle. Cone Shaped Containers: when the rotational rubber brushes of the Forcing Device force the sleeve into the required position on the bottle unevenly causing the printing on the shrunk sleeve to become deformed. When the V-type Belts of the Holding Device cannot hold the bottle at the required level to apply the sleeve. When the surface of the container or substrate is very sticky and the rotational rubber brushes of Forcing Device cannot force the sleeve into the required position. H. CONVEYOR The Conveyor is made from 304 stainless steel and driven by one 1/2 HP Geared Motor which is controlled by one 1 HP Inverter. I. SHRINK TUNNEL a) Main Structure The Main structure has a height adjustable system. The height of the tunnel is adjustable range of 500mm. The height of the main structure can be adjusted with the leveling legs; the range of this adjustable height is 75mm maximum. These are the dimensions of the standard Shrink Tunnel: 1600 mm length, 420 mm width, and 800 mm height. There are 12 heating elements (1kW ea) in the Shrink Tunnel. The temperature can be adjusted up to 400 C. J. Preheating Device Option After the container leaves the Holding Device, there are some conditions when the sleeve doesn t remain in the proper position and has the tendency to slip or move on the container during shrinking. The Preheating Device will solve this problem. The Preheating Device is situated before the Shrink Tunnel and will heat two points of the shrink label securing the label to the container, from here the label will maintain the correct position and the final shrinking can be accomplished with accuracy. KARLVILLE DEVELOPMENT LLC 10 REV SM2-007
ELECTRIC SHRINK TUNNEL Control Panel Shrink Tunnel Height-Adjust Handle Main Structure Leveling Screws FRONT VIEW SIDE VIEW KARLVILLE DEVELOPMENT LLC 11 REV SM2-007
2. MAIN CONTROL PANEL A. MAIN CONTROL PANEL DESCRIPTION. TOUCH SCREEN POWER SWITCH OPERATION EMERGENCY RESET Main Operative Interface. The different parameters and operation settings to control the machine can be set in this touch screen interface. This selector turns the control power On/Off. This selector enables or disables the infeed screw, the one that feeds the containers into the application unit. Emergency Stop Button. In a machine s emergency situation, activate the emergency push button, pushing it. Pull it, to release the emergency button. This push button resets the internal safety relay. Every time the machine is powered on, this push button should be activated, to reset the safety relay. If an emergency button is activated, after this emergency button is released, the RESET button should be activated to reset the internal safety relay. KARLVILLE DEVELOPMENT LLC 12 REV SM2-007
3. INSTALLATION The machine has been fully adjusted and calibrated at the factory. Do not do any inner adjustment of it unless necessary. A. Installation instructions a) Unpacking the machine: This machine will be shipped an enclosed in wood crate or plate. Remove the locking bolts and metallic belts that hold the machine to the skid. Using suitable lifting equipment, unload the machine and the shrinking tunnel from the crate and move it to the final position. Check the shipped parts against the part list. Working area and safety: Ensure that the floor where the machine and shrink tunnel will be positioned is even and strong enough to support the machine. The area in which the machine will be positioned should be dry and well ventilated. b) Fittings. Some parts could have become loose during the shipment. Make sure all parts are properly tightened and adjusted. c) Leveling the machine. After the application machine and the shrinking tunnel have been positioned, use a precision level equipment to level the machine. Put the support legs under the applicator base and level the machine adjusting the leveling bolts on each corner. Follow the same procedure to level the shrink tunnel. The support legs on the applicator, also will help to adjust the conveyor height. d) Power Requirements The power supply must match the power requirements of the machine. It is very important to ground the machine, for preventing electric shocks and other injuries. Check the rotation of the motors and verify they are running in the right direction. If they are not running in the right direction, change phases of the input power. KARLVILLE DEVELOPMENT LLC 13 REV SM2-007
The electric systems on this machine comply with the wiring and manufacturing regulations of International Standard Electrical Laws. Power requirements are shown on the page 1 of this manual; voltage must be within ±5% range. Conveyor Gear Motor. The wiring between conveyor gear motor and The Application Machine must be disconnected before shipping. The conveyor must be assembled before wiring the gear motor. The cable that is not connected outside of the Application Machine is for the Conveyor Gear Motor. Open the terminal box of conveyor gear motor and then connect the reserved cable into the terminal box according to the cable mark. Power Supply of Sleeve Applicator Machine 220V / 3 Phases. Use four wires, 3.5 mm 2 cross section cable to connect the power supply for Sleeve Machine. Open the electrical cabinet and then connect the R, S, and T Phase of cable into the breaker of Sleeve Machine. The ground line is connected with any screw of base cabinet. 380V / 3 Phases. Use four wires, 3.5 mm 2 cross section cable to connect the power supply for the machine. Open the electrical cabinet and connect the R, S, T, and G Phase. The ground line is connected on any screw of base cabinet. After connecting the power supply, turn the machine on and check that the direction of the Slip-On Rollers rotation is correct. The Slip-On Rollers should drive the shrink sleeve down. If the Slip-On Rollers drive the sleeve up, change any of two R, S, T phases wiring at the power input. Power Supply of Shrink Tunnel 220V / 3 Phases. The Shrink Tunnel will reserve one 5 meters length cable for wiring. Use four wires and 8.0 mm 2 cross section cable to connect the power supply for the Shrink Tunnel. 380V / 3 Phases. The Shrink Tunnel will reserve one 5 meters length cable for wiring. Use four wires and 5.5 mm 2 cross section cable to connect the power supply for the Shrink Tunnel. After connecting the power supply, turn on the Shrink Tunnel and verify the correct rotation of the fans. KARLVILLE DEVELOPMENT LLC 14 REV SM2-007
e) Assemble the Conveyor The Conveyor will be separated into four parts for shipping. There are three conveyor bases and one conveyor top chain. The middle part of conveyor base is fixed on Applicator Machine and it can t be moved. Insert the right conveyor base complete with pedestals into the right side of the middle conveyor base and then secure it up with the locking screws. Insert the left conveyor base complete with pedestals into the left side of the middle conveyor base and then screw up. Connect the top chain of conveyor onto conveyor base. f) Install the Shrink Tunnel Move the shrink tunnel into the required position that must be on top of the conveyor. Tighten the supports pads until the Shrink Tunnel can t be moved by hand. Adjust the height of Shrink Tunnel until the bottom of the Shrink Tunnel is at the same height of the top of conveyor. KARLVILLE DEVELOPMENT LLC 15 REV SM2-007
4. TOUCH SCREEN OPERATING INSTRUCTIONS. INITIAL SCREEN Screen Instructions CUTTER HOME CLEAR DRIVES FAULTS ACCESS LEVEL This button commands the Cutting Servo System to go to its home position. This order will be overridden if one of the safety doors is open, the safety relay is on and the Operation On command is not activated on the Automatic or Manual Mode Screens. This button resets all the possible faults on the AC Motor Electronic Drives. This button opens the access screen. On the access screen there are three different access levels: Operator, Engineering and Designer Level. To access to Engineering and Designer s levels it is required a password entry. The Operator s Level is the default level and no password is required, not even access this screen, just push the Main Function Screen. KARLVILLE DEVELOPMENT LLC 16 REV SM2-007
MAIN FUNCTION SCREEN Screen Instructions ACCUMULATOR & MONITOR Push this button to go to the Accumulator and Monitor Screen. The operating modes and setting options on that screen appear next to this button. CUTTING MODE Push this button to go to the Cutting Mode Screen. The operating modes and setting options on that screen appear next to this button. MANUAL MODE Push this button to go to the Manual Mode Screen. The options on that screen appear next to this button. AUTOMATIC MODE Push this button to go to the Automatic Mode Screen. The available commands are shown next to this button. SHRINK TUNNEL Push this button to go to the Shrink Tunnel Parameter Settings SCREEN Screen. The available commands are shown next to this button. MAIN FUNCTION Push this button to go to the previous screen. SCREEN KARLVILLE DEVELOPMENT LLC 17 REV SM2-007
CUTTING MODE SCREEN Screen Instructions UNPRINTED/PRINTED MATERIAL LENGTH SPEED Push this button to select the Unprinted Material Cutting Mode or Printed Material Cutting Mode. In Unprinted Material Cutting Mode the cutting system follows the length set in this screen. This mode is normally used for non printed or continuous printing materials. The optical sensor is not used in this mode. The Printed Material Cutting Mode is used to register the cutting with the printing and cut printed material precisely. The system uses an optical sensor that detects the clear area between every label. The sensor has a position adjusting system and its position can be adjusted to get the cut on the right spot. If the cutting is not in the exact required spot, the sensor position should be adjusted until it reaches the required position. In this mode, the length setting on this screen is ignored. This numeric entry sets the required length when the Unprinted Cutting Mode is selected. Unit: mm This numeric entry sets the required label-shooting system speed. When an application requires a higher speed, this parameter should be increased, but also the conveyor speed, the V-Type Belts speed and the Feeding Screw s speed should be increased. The position of the container detecting sensor should be adjusted also. KARLVILLE DEVELOPMENT LLC 18 REV SM2-007
FEEDING SPEED ALARM RESET AUTOMATIC MODE MANUAL MODE HEAT TUNNEL SPEED AND CONTROL SETTINGS SETTINGS CUTTING MODE SCREEN This numeric entry sets the feeding Jog speed. This only will be effective when in manual mode the Feed Label command is activated. There are several conditions in which the machine will initiate an alarm procedure. The machine will stop and an audible buzzer will be activated. The Alarms Screen, will show the problem. This push button will deactivate the buzzer when pushed. Push this button to go to the Automatic Mode Screen. Push this button to go to the Manual Mode Screen. Push this button to go to the Shrink Tunnel Parameter Settings. Push this button to go to the Speed and Control Settings Screen. Push this button to go to the Settings Screen. Push this banner to go to the previous screen. KARLVILLE DEVELOPMENT LLC 19 REV SM2-007
MANUAL MODE SCREEN Screen Instructions MAIN OPERATION OPERATION MODE CUT FEED FEED ONE LABEL This button enables the machine s entire operation. If Operation is off, the Servo Motors System will be disabled and its operation as well. This button selects the Application Mode, Automatic or Manual. This is one of the manual functions available on this screen. This push button activates the cutter once when pushed. Verify that there is NO material blocking on the bullet on this area. If the cutter is activated and there is material jammed in this area, the blades can be seriously damaged and the servo motor system can be overloaded and consequently damaged. This is one of the manual functions available on this screen. This push button continuously feed sleeve into the bullet when pushed. Activates the Feeding Servo Motor. This is one of the manual functions available on this screen. This push button feed automatically only one label at the time when pushed. Depending on the Cutting Mode selected, it will follow the length or the sleeve registration transparent mark. KARLVILLE DEVELOPMENT LLC 20 REV SM2-007
LABEL HOME FEEDING SCREW V-TYPE BELTS FORCING BRUSHES ALARM RESET MAIN PLATFORM This button registers the material with the registration sensor. When pushed, it will feed label until the material reaches the transparent detecting point, the stops: The material will be registered with the detecting sensor position. This push button turns the Feeding Screw on when pushed once. To turn it off, push it again. The conditions for this screw to operate are the following: 1. The Machine should be in Automatic Mode. 2. The external switch located in front of the feeding screw and on the Main Operator Control Panel should be turned ON. 3. There must be containers to feed on the conveyor, if the SENSOR at the beginning of the conveyor detects no containers, the machine s computer automatically will stop the feeding screw, following an OFF DELAY function. As soon containers are detected on the conveyor, the Feeding Screw will start its operation. 4. If a container blocking is detected at the end of the conveyor by the SENSOR located here, the machine s computer will automatically stop the feeding screw. If the blocking is cleared, the Feeding Screw will turn on again automatically following an On Delay function. 5. The Data Code Printer should be in Ready status. 6. The Accumulator must be operating normally, if the accumulator platform raises up to the upper limit, the feeding screw will be stopped. This push button turns the V-Type Belts System on when pushed once. To turn it off, push it again. This push button turns the Forcing Brushes on when pushed once. To turn it off, push it again. There are several conditions in which the machine will initiate an alarm procedure. The machine will stop and an audible buzzer will be activated. The Alarm Screen, will show the problem. This push button will deactivate the buzzer when pushed. This buttons move up or down the main application platform. KARLVILLE DEVELOPMENT LLC 21 REV SM2-007
AUTOMATIC MODE CUTTING MODE VACUUM BLOWERS SPEED & CONTROL SCREEN ALARM SCREEN Push this button to go to the Automatic Mode Screen. Push this button to go to the Cutting Mode Screen. Push this button to go to the Vacuum Blowers Control Screen. Push this button to go to the Speed And Control Screen. Push this button to go to the Alarm Screen. MANUAL MODE Push this banner to go to the previous screen. SCREEN For these functions to operate, the Main Operation Switch must be in the ON position, otherwise these functions will not operate when the buttons pushed. KARLVILLE DEVELOPMENT LLC 22 REV SM2-007
AUTOMATIC MODE SCREEN Screen Instructions MAIN OPERATION OPERATION MODE START STOP COUNTER RESET ALARM RESET This button enables the machine s entire operation. If Operation is off, the Servo Motors System will be disabled and its operation as well. This button selects the Application Mode, Automatic or Manual. This button starts the complete automatic operation. This button, The Conveyor, The Feeding Screw, and the Operation Main Switch must be on the ON status for the machine to operate in automatic mode. If the emergency stop is being pushed, the security system should be reset for the machine to work on the Automatic Mode. When the Automatic mode has been started the green light on the beacon lights will be on. This button will stop the automatic application operation. This window shows the actual quantity of labels applied on containers. This button resets the counter. There are several conditions in which the machine will initiate an alarm procedure. The machine will stop and an audible buzzer will be activated. The Data Screen I, will show the problem. This push button will deactivate the buzzer when pushed. It also shows if any Emergency Stop is activated. KARLVILLE DEVELOPMENT LLC 23 REV SM2-007
FEEDING SCREW V-TYPE BELTS FORCING BRUSHES This push button turns internally the Feeding Screw on when pushed once. To turn it off, push it again. The conditions for this screw to operate are the following: 1. The Machine should be in Automatic Mode. 2. The external switch located in front of the feeding screw and on the Main Operator Control Panel should be turned ON. 3. There must be containers to feed on the conveyor, if the SENSOR at the beginning of the conveyor detects no containers, the machine s computer automatically will stop the feeding screw, following an OFF DELAY function. As soon containers are detected on the conveyor, the Feeding Screw will start its operation. 4. If a container blocking is detected at the end of the conveyor by the SENSOR located here, the machine s computer will automatically stop the feeding screw. If the blocking is cleared, the Feeding Screw will turn on again automatically following an On Delay function. 5. The Data Code Printer should be in Ready status. 6. The Accumulator must be operating normally, if the accumulator platform raises up to the upper limit, the feeding screw will be stopped. This push button turns the V-Type Belts System on when pushed once. To turn it off, push it again. This push button turns the Forcing Brushes on when pushed once. To turn it off, push it again. MAIN PLATFORM MANUAL MODE CUTTING MODE This buttons move up or down the main application platform. If the Platform doesn t move when this buttons are pushed, this could be caused by the following conditions: The platform has reached the upper or the lower limit switches. The emergency button is activated. The electric security system hasn t been reset. Push this button to go to the Manual Mode Screen. Push this button to go to the Cutting Mode Screen. KARLVILLE DEVELOPMENT LLC 24 REV SM2-007
VACUUM BLOWERS SCREEN SPEED AND CONTROL SCREEN ALARM SCREEN AUTOMATIC MODE SCREEN Push this button to go to the Vacuum Blower Control Screen. Push this button to go to the Speed and Control Screen. Push this button to go to the Alarms Screen. Push this banner to go to the previous screen. KARLVILLE DEVELOPMENT LLC 25 REV SM2-007
ACCUMULATOR AND MONITOR SCREEN Screen Instructions ACCUMULATOR UPPER POSITION SPEED MONITOR ACCUMULATOR SCREEN This button will raise the Accumulator Platform to allow the label to be threaded on this unit. Once the Accumulator Platform reaches the upper position, the button will show Upper Position Reached. Once the accumulator is threaded, the selector marked Load Accumulator should be activated to load the material into the accumulator. This selector is located on the separate unwind unit. Once the accumulator stops loading the material, the selector should be deactivated to allow the automatic system to takeover the unit control. This window shows the Machine s Application Speed. Push this banner to go to the previous screen. KARLVILLE DEVELOPMENT LLC 26 REV SM2-007
HEAT TUNNEL SCREEN Screen Instructions BLOWER This button starts the Air Blower on the Zone 1 (Left)/ Zone 2 (Right). FRONT HEATER This button turns on/off the Front Heaters on the Zone 1 (Left)/ Zone 2 (Right) FRONT TEMPERATURE This numeric entry sets the desired temperature of the front SET POINT section on the Zone 1 (Left)/ Zone 2 (Right). FRONT ACTUAL This window shows the front actual temperature of the front TEMPERATURE section on the Zone 1 (Left)/ Zone 2 (Right). REAR HEATER This button turns on/off the Rear Heaters on the Zone 1 (Left)/ Zone 2 (Right). REAR TEMPERATURE This numeric entry sets the desired temperature of the Rear SET POINT section on the Zone 1 (Left)/ Zone 2 (Right). REAR ACTUAL This window shows the front actual temperature of the Rear TEMPERATURE section on the Zone 1 (Left)/ Zone 2 (Right). HEAT TUNNEL SCREEN Push this banner to go to the previous screen. KARLVILLE DEVELOPMENT LLC 27 REV SM2-007
SPEED AND CONTROL SCREEN Screen Instructions FEEDING SCREW SPEED MAIN CONVEYOR SPEED FORCING BRUSHES SPEED SHOOTING ROLLERS SPEED V-TYPE BELTS SPEED MAIN FUNCTION SCREEN HEAT TUNNEL SETTINGS VACUUM BLOWERS TENSION SETTINGS SETTINGS This numeric entry sets the desired speed of the Feeding Screw Motor. The button next, starts/stops internally the Feeding Screw motor. This numeric entry sets the desired speed of the Main Conveyor Motor. The button next, starts/stops internally the Main Conveyor motor. This numeric entry sets the desired speed of the Forcing Brushes Motor. The button next, starts/stops internally the Forcing Brushes motor. This numeric entry sets the desired speed of the Shooting Rollers Motor. The button next, starts/stops internally the Shooting Rollers motor. This numeric entry sets the desired speed of the V-Type Belts Motor. The button next, starts/stops internally the V-Type Belts Motor. Push this button to go to the Main Function Screen. Push this button to go to the Heat Tunnel Settings Screen. Push this button to go to the Vacuum Blowers Control Screen. Push this button to go to the Tension Settings Screen. Push this button to go to the Settings Screen. KARLVILLE DEVELOPMENT LLC 28 REV SM2-007
SPEED & CONTROL SCREEN Push this banner to go to the previous screen. KARLVILLE DEVELOPMENT LLC 29 REV SM2-007
VACUUM SYSTEM SCREEN Screen Instructions VACUUM BLOWERS 1-2-3-4 AUTOMATIC MODE MANUAL MODE SPEED & CONTROL SCREEN HEAT TUNNEL SETTINGS SETTINGS The green button turns on the Blower 1/2/3/4, the button next stops the related blower. Push this button to go to the Automatic Mode Screen. Push this button to go to the Manual Mode Control Screen. Push this banner to go to the previous screen. Push this button to go to the Heat Tunnel Settings Screen. Push this button to go to the Settings Screen. VACUUM SYSTEM SCREEN Push this banner to go to the previous screen. KARLVILLE DEVELOPMENT LLC 30 REV SM2-007
SETTINGS SCREEN Screen Instructions ACCUMULATOR INFEED MOTOR ACCELERATION ACC UMULATOR INFEED MOTOR DECELERATION ACC UMULATOR OUTFEED MOTOR ACCELERATION ACC UMULATOR OUTFEED MOTOR DECCELERATION MAIN INFEED MOTOR ACCELERATION MAIN INFEED MOTOR DECELERATION FEED SERVO MOTOR ACCELERATION FEED SERVO MOTOR DECELERATION This numeric entry sets the acceleration type desired of the Accumulator Infeed Motor. This numeric entry sets the deceleration type desired of the Accumulator Infeed Motor. This numeric entry sets the acceleration type desired of the Accumulator Outfeed Motor. This numeric entry sets the deceleration type desired of the Accumulator Outfeed Motor. This numeric entry sets the acceleration type desired of the Main Infeed Motor. This numeric entry sets the deceleration type desired of the Main Outfeed Motor. This numeric entry sets the desired acceleration of the Feeding Servo Motor. This value will be used only when the system is operating in Manual Mode. This numeric entry sets the desired deceleration of the Feeding Servo Motor. This value will be used only when the system is operating in Manual Mode. KARLVILLE DEVELOPMENT LLC 31 REV SM2-007
CUT SERVO MOTOR SPEED CUT SERVO MOTOR ACCELERATION CUT SERVO MOTOR DECELERATION SETTINGS SCREEN II This numeric entry sets the desired speed of the Cut Servo Motor. This value will be used only when the system is operating in Manual Mode. This numeric entry sets the desired acceleration of the Cut Servo Motor. This value will be used only when the system is operating in Manual Mode. This numeric entry sets the desired deceleration of the Cut Servo Motor. This value will be used only when the system is operating in Manual Mode. Push this button to go to the Settings Screen II. KARLVILLE DEVELOPMENT LLC 32 REV SM2-007
SETTINGS SCREEN II: TENSION Screen Instructions ACCUMULATOR This numeric entry group sets the desired speed steps (1 to 6) INFEED MOTOR of the Accumulator Infeed Motor. ACCUMULATOR This numeric entry group sets the desired speed steps (1 to 6) OUTFEED MOTOR of the Accumulator Outfeed Motor. MAIN INFEED MOTOR This numeric entry group sets the desired speed steps (1 to 6) of the Main Infeed Motor. SETTINGS SCREEN II: Push this banner to go to the previous screen. TENSION KARLVILLE DEVELOPMENT LLC 33 REV SM2-007
ALARM SCREEN Screen Instructions This Screen shows clearly all the possible alarms and faults on the machine s operation. CLEAR DRIVES This button resets all the possible faults on the Electronic AC Motor FAULTS Drives. CLEAR SERVO This button resets all the possible faults on the Electronic Servo Motor DRIVES FAULTS Drives. ALARMS Push this banner to go to the previous screen. SCREEN I KARLVILLE DEVELOPMENT LLC 34 REV SM2-007
5. OPERATION Automatic Operation Description CONTAINER DETECTION LABEL FEEDED (MEASURED OR PRINT DETECTED) LABEL CUT LABEL ACCUMULATED / SHOT A. Container Detection. The container is detected entering to the shooting area by the Container Detecting Sensor. The position and height of this sensor is adjustable and must be adjusted depending on the conveyor speed, the Feeding Screw speed and the size of the container. a) Container Detecting Sensor. This sensor is reflective type and uses a mirror. If the position of the sensor is adjusted, the mirror s position also needs to be adjusted. Generally the sensor sensitivity will be calibrated at the factory and it will not be necessary to readjust. However when the operating environment or the container s material have changed, the sensitivity of the sensor may need to be adjusted. If the label is not shot accurately on the container, the Container Detecting Sensor position should be adjusted. The label shooting position will change if the conveyor speed is changed. It will cause the Slip-On Rollers to not shoot the sleeve on to the container accurately. The position of Bottle Position Detecting Sensor needs to be changed to solve this issue. If the Slip-On Rollers shoot the sleeve too early, as shown on the figure A of the drawing, move the sensor in the right direction until the sleeve is applied accurately on the container figure B of the drawing. If the Slip-On Rollers shoot the sleeve too late, as shown on the figure C of the drawing, move the sensor in left direction until the sleeve is applied accurately on the container figure B of the drawing. Directions are giving assuming that the conveyor runs from left to right direction. KARLVILLE DEVELOPMENT LLC 35 REV SM2-007
Positioning of the Container Detecting Sensor Adjusting the Sensor Sensitivity. When there is no container between the sensor and the reflection mirror, the sensor is active and the light of sensor will be on. If the light is off, adjust the sensitivity of sensor until the light turns on. When there is a container between the sensor and the reflection mirror, the sensor should be inactive and the light of the sensor should be off. If the light is on, adjust the sensitivity of sensor until the red light turns off. B. Label Feeding. The label is fed trough the feeding rollers. The feeding can be accomplished in two different ways, measuring a specific length (Unprinted Material) or following the printing of the label (Printed Material). C. Label Cut. The label is cut. Once the label is cut, the individual label remains in the same position; it will be the next label the one that will push it down to Slip-On Rollers. If the cutting position of sleeve is incorrect, adjust the height of the Sleeve Detecting Sensor by adjusting the knob and changing the cutting position. KARLVILLE DEVELOPMENT LLC 36 REV SM2-007
Cutting Position Adjustment (Printed Material Mode) When the cutting position is lower than the required position, lower the height of the Sleeve Detecting Sensor. When the cutting position is higher than required position, raise the height of Sleeve Detecting Sensor. The sensor will be optimized at the Factory and it is not required to be readjusted. However when the specification of sleeve varies too much, it may be necessary to adjust the sensitivity or position of the sensor. As seen in drawing, loosen the screw of sensor optical terminals and then move them to required positions. Both of them can move independently but they must be positioned in straight line otherwise the sensor will not work efficiently. Sensitivity Adjustment When the sensor light passes through the sleeve, the green indicator led on the sensor will turn on. Otherwise the green led will be off. Position the sensor light exactly on the clear area of the sleeve and adjust the Sensitivity Potentiometer on the sensor until the green led turns on. D. Label Accumulated/ Shot. Given that is the next label the one that pushes the previous one to the Slip-On Rollers. As soon as the label reaches the Slip-On Rollers, these ones shoot the label down at high speed. The Slip-On Rollers should be in the proper position, making contact with the bearings on the Holder. There are two mechanisms that adjust the position of the Slip-On Rollers. The KARLVILLE DEVELOPMENT LLC 37 REV SM2-007
height adjustment mechanism and the mechanism that adjust the distance between the two rollers. The tightness of these rollers can be adjusted with the second mechanism that moves them in or out (Adjusting the distance in between). Tight these rollers against the bearings, being sure that the sleeve is being pulled. The tightness needed is only the necessary to pull the material down. KARLVILLE DEVELOPMENT LLC 38 REV SM2-007
6. OPERATING PROCEDURE Power The Machine On Turn Main Operation On (Automatic and Manual Mode Screens) Command the Cut Servo Motor to Reach the Home Position (Initial Screen) Set the machine in Manual Mode Thread the sleeve on the machine On the Touch Screen, push the Label Home button if operating in Printed Material Cutting Mode. If operating in Unprinted Material Cutting Mode, push the Feed button continuously until the sleeve is driven through the cutter, stop feeding the material in. Push the Feeding One Label button once to feed one piece of sleeve. Push the CUT button for two seconds to cut the sleeve below the cutter and remove it. Set the machine in Automatic Mode and push the Start button to initiate the automatic operation. Verify that the system is working properly, interrupting twice the Container Detecting Sensor, two labels should be shot down. Check the cutting position and if applicable, the perforation s position. If necessary make fine adjustments to the corresponding systems. Turn the Conveyor, the Feeding Screw and The Forcing Brushes On. Set the Conveyor s speed, The Feeding Screw s speed and the Container Detecting Sensor proper position, synchronize them. Start feeding containers turning on the switch on the front of the Feeding Screw, allow one container to go on the application area and verify if the system is applying the label precisely, if needed, adjust the position of the Container Detecting Sensor. Set the Conveyor s speed, The Feeding Screw s speed and the Container Detecting Sensor proper position, synchronize them. Verify the unwind tension of the Sleeve and let the machine run in automatic mode. KARLVILLE DEVELOPMENT LLC 39 REV SM2-007
ACCUMULATOR OPERATION DESCRIPTION New Material needs to be loaded on the Accumulator. Load the two reels on the Unwind Unit. On the Accumulator Screen on Main Operator s Control Panel Touch Screen, push the Raise the ACC Platform. The platform will raise to the upper limit and stop. Release the Accumulator Infeed Nip Roller and proceed to thread the material on the Accumulator. Once the material is threaded on the accumulator, engage the Infeed Nip Roller. Once the label is threaded on the Accumulator and the Infeed Nip Roller engaged, activate the Load Selector located on the Unwind Control Cabinet, the Accumulator Infeed Motor will start loading the sleeve into the Accumulator until it reaches the next sensor down, then it will stop feeding material. At this point, the Load Selector should be deactivated, the unwind unit will automatically control the sleeve tension after. The material has been loaded successfully. Sleeve has finished on the reel. Lock the label with the locking bars on top of the Unwind Unit. The next running reel should be mounted on the secondary unwinder already. make the splice, following the standard splicing procedure. Proceed to Release the locking bar to release the sleeve. The accumulator will automatically load the film regardless of the accumulator s platform. If this platform reaches the upper limit, the container s feeding screw will stop. KARLVILLE DEVELOPMENT LLC 40 REV SM2-007
7. APPENDIX A. Shrink Tunnel Operation Procedure a) Turn on the Power Switch of the Electric Shrink Tunnel. b) Turn on the Blowers. c) Turn on the Heaters Switch. d) Set the primary and secondary Temperature Set Points to the required temperature setting. e) Wait until the temperature required has been reached on the both heating areas. When the temperature has been reached the shrinking operation can be initiated. f) In order to optimize the shrink quality, the Tunnel s Height, The Temperature of the Primary or Secondary set of heaters and the grid opening area can be adjusted. g) To turn off the Tunnel, turn off the heaters first. The Fan should be on until the temperature drops down to the room temperature. Once the heater s temperature dropped down, turn the Fan off and finally the Power Switch can be turned off. CONTROL PANEL ELECTRIC SHRINKING TUNNEL INDICATING LAMPS FAN SWITCH HEATERS SWITCH POWER SWITCH PRIMARY TEMPERATURE KNOB PRIMARY TEMPERATURE KNOB KARLVILLE DEVELOPMENT LLC 41 REV SM2-007
B. Procedure to Replace the Razor Blades on the Cutting System Follow the drawing instructions to replace the razor blades on the cutting system. Once the new blades have been exchanged, verify their symmetry and functionality, manually rotating the blades from the external actuating gear. Set the blades initial position following the KARLVILLE DEVELOPMENT LLC 42 REV SM2-007
C. Lubrication Conveyor Metal Chain - Daily Linear Motion Guide of Tension Control Device - Every Week Operating Platform Height Moving Screw - Every Month Gear of Bottle Feeding Device - Every Month Sliding Bars on the Accumulator Unit - Every Month D. Trouble Shooting Sleeve Jammed On the Holder If the sleeve accumulates on the Holder, remove the accumulated sleeve material and rethread the sleeve on the machine. Initiate the operation again. Do the following checks if this problem becomes repetitive: Switch to Manual Mode. Push the Feeding One Label button once and check whether the Driving System only draw one label through cutter or not. If one label is not fed trough the cutter, adjust the sensitivity of the Sleeve Detecting Sensor and check again. If the system is not feeding one label, check the terminals of the Sleeve Detecting Sensor. Disconnect and reconnect them and adjust the sensitivity, verify if the problem has been solved. If the system is not feeding one label, the Sleeve Detecting Sensor must be damaged and needs to be replaced. Push the Cut button once and check if the sleeve is completely cut off or not. Check if the cutting system is cutting the sleeve when the Cut button is being pushed. If the cutting quality is not good enough, replace the old razor blades. If the cutting system is not cutting the label at all, check if the Servo Drive is tripped down, if it s showing a fault, restart the machine and eliminate the failure. Check the cutting system again. If the previous test results are positive, the probable cause of the jamming of the material on the Holder could be: Poor seal quality of the sleeve. Wrong Layflat of the sleeve, or high variations of the sleeve s Layflat. KARLVILLE DEVELOPMENT LLC 43 REV SM2-007
Sleeve Cutting Off Incompletely and/or Uneven Cutting Surface This problem could be caused by worn razor blades. To solve the problem Replace the razor blades. Incorrect Cutting/Perforation Position Adjust the position of the Cutting/Perforation system. Poor Shrinking Performance of the Shrunk Sleeve The shrinkage is incomplete. Raise the primary and secondary temperature or secondary temperature only of Shrink Tunnel. Re adjust the air grid openings to increase the hot air volume where is required or close it where it is not required any air flow. There are wrinkles on the shrunk sleeve. The Picture of the shrunk sleeve is deformed. The temperature of the primary set of heaters is too high. Lower the primary temperature of Shrink Tunnel. The container fall down after the application Check if the V belts are pressing the bottle from both sides too tightly or if the speed difference between the V-belts and the Conveyor is too much. Make the proper corrections. The Slip-On Rollers cannot shoot the sleeve accurately on the container Adjust the position of the Container Detecting Sensor. Increase the Speed of the Shooting System. This can be accomplished in the Cutting Mode Screen on the Touch Screen. If the problem persists, slow the conveyor speed down and try again. In all cases, the machine has several alarm screens that will appear every time an alarm is activated for a failure on the operation of the machine. KARLVILLE DEVELOPMENT LLC 44 REV SM2-007
E. Machine Threading Drawing KARLVILLE DEVELOPMENT LLC 45 REV SM2-007