IMCF- MS800 Series of FFS Machinery INTERNATIONAL MACHINE CONCEPTS WELCOMES YOU TO YOUR NEW MACHINE Operation Manual: Date 2015. Version 2. Serial Number 1
CONTENTS Chapter 1 Machine Description 1.1 Uncrating Instructions 1.2 Installation 1.3 Electrical and Pneumatic connections 1.4 Chapter 2 Technical Parameters and Description 2.1 Chapter 3 Operation Instruction Packaging material loading 3.1 Computer screens and description 3.2 Mechanical description and adjustments 3.3 Film adjustments 3.3.1 Vertical sealing roller adjustments 3.3.2 Horizontal sealing roller adjustment 3.3.3 Funnel adjustment 3.3.4 Vertical slitting knife adjustment 3.3.5 Funnel removal 3.3.6 Filling volume adjustment 3.3.7 Cutting system adjustments 3.3.8 Eye mark registration adjustments 3.3.9 Chapter 4 Malfunctions (Faults) and their rectification Table of possible faults 4.1 Chapter 5 Maintenance Instructions 5.1 Chapter 6 List of main Mechanical Parts 6.1 List of main Electrical Parts 6.2 Chapter 7 Electrical Diagrams 7.1 2
Chapter 8 Temperature controllers 8.1 Servo Driver Manual 8.2 Servo Drive Parameter setting list 8.3 Pneumatic vacuum charging machine 8.4 Multi- head Ink Roll Coder 8.5 Chapter 9 Spare parts list 9.1 3
Chapter 1 1.1 Machine Description The IMCF- 800 Automatic Powder packaging machine is a high quality efficient machine which Fills, Forms and Seals bags from rolls of packaging material. The functionality of the machine is such that a roll of film is formed through a forming shoulder into the correct bag width. Vertical seals then form the center back seal. The machine has an intermittent- type function and as such the various functions such as filling, sealing and cutting take place while the bag is in a stationary position. Bag length control can be controlled either by a registration mark printed on the film or by length control set on the computer screen. The formed bag will be fed downwards and then a bottom seal will be performed. Once a center back seal and a bottom seal have formed the bag, the bag will be filled. The powder fill control volume will be controlled via the computer interface. The filling of the bag is processed by an augur- filling device that is driven by a servo motor. The number of revolutions of the augur will determine the fill volume that is applied to the bag. The speed of the augur can also be set at different speeds so the speed of filling of the bag can be controlled. Powders of a more fluid nature can be run faster, and difficult non- fluid powders must be run at a slower speed. The entire machine can also be speed- adjusted via an electronic speed controller. Running the machine too fast might result in bags being inconsistent and not sealed correctly. It must also be remembered that the faster the machine runs the higher the sealing temperature will be as there will be less sealing dwell time on the sealing cycle (i.e. sealing elements closed and in contact with the film). The machine is capable of running registered print and as such is fitted with a photo- electric cell that can pick up a dark registration mark printed on the film. Exact set up this is covered in Chapter 3. Correct setting up of the machine is essential for correct operation and specific attention should be paid to the following areas. Centralizing of the film correct alignment of the forming shoulder The vertical sealing elements The pull down rolls The cutting blade The correct alignment of the augur filling tube NOTE: all these areas will be covered in a later chapter (Chapter3) 4
This machine cannot use materials that are not composite. The recommended film is PET/PE. However various types of films can be accommodated as long as the outside film melts at a lower temperature than the inner film. PET/plated, AL/PE, PET/PE, PAPER/PE, NYLON, etc. The packaging film roll should not weigh in excess of 60kg and its inner core should be no greater than 75mm. The specific former fitted to the machine will determine the film width to be run on the machine. 1.1 Un- crating Instructions During un- crating make sure that no physical damage to the outside of the crate has taken place. Carefully break open the exterior panels to reveal the machine and its working parts. The machine will be covered in a plastic protective cover. This is to be removed. Make sure that no parts have been damaged during transport, or fallen off the machine. The machine will arrive with certain parts dis- assembled. These need to be fitted to the machine to resemble the photos above the machine. The machine is fixed to the wooden palett by four metal brackets. Remove these brackets and discard or keep for future use. The doors and covers have been taped closed for safety reasons, these taped parts can now be opened. Surface rust can take place due to the excessive sea sir during shipping. This will only be surface rust and a dry cloth should be used to remove this rust residue. The entire machine has bee shipped with an oil coating on the surface to safeguard the machine from corrosion. This can now be removed with a very light detergent. The non- stainless steel parts should be re- oiled to prevent rusting taking place after cleaning. Do not leave the machine wet. The machine is top- heavy and as such, care should be taken when handling the machine and removing it from its wooden pallet. NOTE: DO NOT HANDLE THE MACHINE ON THE FILM BRACKETS OR ROLLERS. These parts are critically aligned and should they be bent out of position the film may run off. 5
v 1.2 Installation Only a qualified technician should perform the machine installation or a suitably trained person. Note: it is dangerous to work on a moving machine and the machine should be off and isolated before any form of work is performed. Machine should be placed in a well- ventilated room, free from dust and excessively corrosive materials. There should be at least 1,5m space around each side of the machine for convenient operation and maintenance. Prepare the power supply 380V or 220V/50HZ. Three/Single Phase and neutral, and connect to an appropriate earth wire. Pneumatic connections should take place as the designated connection. The air should not be less than 6Bar while the machine is operational. Air should be free of water and contaminants. The machine should be placed on level ground. After installing the machine, check if the machine is level by Level Instrument. If not, please adjust the four legs. Check every part of the machine carefully for damage during shipping. Tighten any loose parts, screws and moving parts. All gearboxes should be checked for sufficient oil. Check all electrical connections for loose wires. Make a test of the machines electrical power and confirm the voltage and earth continuity. All safety connections relative to your own country should be adhered to. Before operating the machine, please lubricate the following parts: across sealing bearing and its bearing holes, longitudinal where sealing the parts needs oil. 1.4 Electrical and Pneumatic connections This machine requires only a single phase connection and earth wire v DISCLAIMER IMC will not be held responsible fir incorrect installation and subsequent failure of the machine due to any installation procedure not being followed. 6
Chapter 2 2.1 Technical Parameters and Description Voltage Power Requirement Dimensions Maximum Film Roll Width Maximum Film Roll Weight Maximum Sachet Width Minimum Sachet Width Maximum Sachet Fill Minimum Sachet Fill Maximum Sachet Length Minimum Sachet Length Maximum Machine Speed Minimum Machine Speed Air Pressure Required Air Volume Required 380 400V at 50Hz + N + earth 17.5Kw 1808*1425*2470mm mm 60 kg s 70mm 60mm 20g (depending on different product) 2g 150mm 60mm 40 Bags/min per lane 10 Bags/min per lane 0.8 Mpa 10L/Min Chapter 3 3.1 Packaging material loading The packaging material should be purchased in a roll with the printing wound on the inside of the roll. The core diameter should be +- 75mm. For ease of operator never use more that 60kg rolls on the machine. For maximum roll diameter consult the Specifications Table. Use the paper reel holder guides on either side of the film roll to hold the material in place. The material should be centralized to the former as shown below. Note: Only loosen the right side guide for film replacement. Vertical Line of former and vertical line of film must be centralized Center line on Film 7 Paper reel holder guides
The film should be threaded through the roller assembly as shown below: The film should be inserted into the former carefully and the paper should not catch on either end of the former, draw down the film through the former making sure the film has a fin seal at the rear that is able to be inserted into the draw down wheels. 8
3.2 Computer screens and description Operation keys Home Screen Display Button IMCF- MS800 Touch Screen Interface Machine Make Push Button English/Chinese Language Option Display Button 2015-02- 03 08:33:57 Date & Time Display Button Week 2 Age of Machine 9
Operation Screen Display Button 0 bags Total amount of bags produced Display Button 0 mm Length of Bag Display Button 0 b/m Amount of bags produced per minute Display Button 0 mm Length at which bag is sealed Display Button 0 Rpm Eccentric adjustment Display Button 0 Vol Volume of eccentric adjustment Push button Adjust the volume of eccentric by 1 vol Push button Length To choose if cutting by length or by eye mark on film Push Button Home Return to Home Screen Push Button Parameters Set up the Machine Parameters Push Button Augur Set up the augur parameters Push Button Alarm To alarm screen Push Button Manual To manual screen to test machine manually Push Button Passwords Set up machine passwords Push Button Bag feed on To turn Film on Push Button Cutter on To turn cutting blade on Push Button Perf. on To turn blade on Push Button Hopper1 on To turn pick & place on Push Button Coder on To turn coder on Push Button Film Left To move film left Push Button Conv. on To turn conveyor on Push Button Bag fill on To fill product 10
Push Button Stirrer on To turn Stirrer on Push button Hopper2 on To turn feeder on Push button Temp. on To turn temperature of element on Push Button Vibrator on To turn vibrator on Push Button Film Right To move film right 11
Parameter Setup Screen Display Button Code Print Pos. 0 Display Button H. Seal. Stop Pos. 0 Display Button Filling Start Pos. 0 Display Button Vibration Time Display Button H. Cut. Upper Pos. 0 Display Button H. Cut. Under Pos. 0 Display Button H. Cut Count 0 Bags Display Button H. Cut. Bag 0 Bags Display Button H. Circumference 0 mm Display Button V. Circumference 0 mm Display Button Syn Pulse 0 Displays the rotation angle of date printing position Displays the rotation angle of horizontal sealing stop position Displays the rotation angle of filling start position Displays the rotation angle of cutter synchronous position Displays the rotation angle of perf. synchronous position Roller circumference Horizontal sealer circumference Display Button Dwell Zero Pos. 0 mm Position of origin Display Button Hopper Feed Delayed Time 0 Sec. Delayed time of feeding Display Button Sensor Logic 1 Push Button Back Return to Precious screen Push Button Alarm To alarm screen 12
Setup 4 Lane Screen Push Button Augur 1 Stop To turn auger 1 off Push Button Augur 2 Stop To turn auger 2 off Push Button Augur 3 Stop To turn auger 3 off Push Button Augur 4 Stop To turn auger 4 off Push button + or - To increase or decrease the augur turning volume Push Button Manual 1 Press on to turn the augur 1 Push Button Manual 2 Press on to turn the augur 2 Push Button Manual 3 Press on to turn the augur 3 Push Button Manual 4 Press on to turn the augur 4 Push Button All Start Turn on all the augurs Push Button All Stop Turn off all the augurs Push Button Alarm To alarm screen Push Button Next Move to the next screen Push Button Back Return to the previous screen Display button 0 Vol. Volume of augur turning Display button 0 R- min Speed of augur rotate per minute 13
Augur Setup Screen Push Button Augur 1 Clockwise Rotation Turn Augur in a clockwise direction Push Button Augur 2 Clockwise Rotation Turn Augur 2 in a clockwise direction Push Button Augur 3 Clockwise Rotation Turn Augur 3 in a clockwise direction Push Button Augur 4 Clockwise Rotation Turn Augur 4 in a clockwise direction Push Button Augur 1 Anti- clockwise Rotation Turn Augur 1 in an anti- clockwise direction Push Button Augur 2 Anti- clockwise Rotation Turn Augur 2 in an anti- clockwise direction Push Button Augur 3 Anti- clockwise Rotation Turn Augur 3 in an anti- clockwise direction Push Button Augur 4 Anti- clockwise Rotation Turn Augur 4 in an anti- clockwise direction Push Button Manual Augur Speed 0 R- Min Manually adjust Augur speed Push Button Alarm To alarm screen Push Button Back Return to previous screen 14
Alarm screen Display Button Horizontal sensor alarm Displays Normal/Fault state of horizontal sealing sensor Display Button Vertical sensor alarm Displays Normal/Fault state of vertical sealing sensor Display Button H. Cutter sensor alarm Displays Normal/Fault State of horizontal cutter sensor Display Button Perf. sensor alarm N/A Display Button No film Fault sensor alarm 15 Displays Normal/Fault state of no film sensor Display Button Horizontal servo alarm Displays Normal/Fault state of horizontal sealing servo Display Button Vertical servo alarm Displays Normal/Fault state of vertical sealing servo Display Button H. Cutter servo alarm Displays normal/fault state of horizontal cutter servo Display Button Perf. Servo alarm Displays Normal/Fault State of blade servo Display Button No film Fault servo alarm N/A Display Button Augur 1 Servo alarm Displays Normal/Fault state of Augur 1 servo Display Button Augur 2 Servo alarm Displays Normal/Fault state of Augur 2 servo Display Button Augur 3 Servo alarm Displays Normal/Fault state of Augur
3 servo Display Button Augur 4 Servo alarm Displays Normal/Fault state of Augur 4 servo Display Button Augur 1 alarm code Displays alarm code of Augur 1 servo Display Button Augur 2 alarm code Displays alarm code of Augur 2 servo Display Button Augur 3 alarm code Displays alarm code of Augur 3 servo Display Button Augur 4 alarm code Displays alarm code of Augur 4 servo Display button Status Displays the status of communication Push Button Back Returns operator to the previous screen Push Button Servo faults explanation To servo faults explanation screen 16
Manual Operation Screen Push Button Film Motor clockwise Push Button Film Motor anti- clockwise Push Button Perf. Clockwise Push Button Perf. Anti- clockwise Push Button Film Feed Manual Push Button Horizontal Sealing Roller Manual Push Button H. Cutter clockwise Push Button H. Cutter anti- clockwise Push Button Film feed registration find Push Button Clamp manual Push Button Clamp separate Push Button Back Push Button Alarm Press on to turn film motor clockwise Press on to turn film motor anti- clockwise Press on to turn blade clockwise Press on to turn blade anti- clockwise Press on to feed film Press on to roll horizontal sealer Press on to turn H. Cutter clockwise Press on to turn H. Cutter anti- clockwise Press to find the eye mark and measure the bag length Turn picking bag off Turn placing bag off Returns operator to previous menu To alarm screen 17
Password Screen Input the Master Password:111 or 123 (not shown in Manual) Display Button 111 Display the current operation password Display Button 123 Display the current lock password 18
Display button 0 Display the lock date in the future Push button Master password To change the master password Push Button Unlock To unlock machine Push Button Unlock screen Push Button Back Return to previous screen Display Button Input Input the unlock password Push button Unlock To unlock machine 19
3.3 Mechanical Description and Adjustment 3.3.1 Film Adjustments Setting up the film is very important, most problems stem from incorrect film set- up and alignment. The film must be set up in the middle of the former, failing to do this will result in the film running off- center to the former and a weak or non- existent center seal will result. Use the film holding guides to centralize the film on the film reel holder bar. Make sure that the reel holder guides are tightened to ensure the film roll does not move during operation. Typical film adjustment as per description will result in successful packets being produced. The film must be aligned in the center of the film holder guide to ensure that there is sufficient adjustment of the film reel for slight re- alignment during running Centralize film in this film holder frame The film will be fed and unwound with the print winding off from the center as shown 20
The film is to be fed upwards through the rollers as shown above and then over the black splitting plate and over the knife. Knife position The cut film will be wound left and right as shown above and through the two blue roller systems as shown. The film will then be fed downwards towards the roller assembly and fed as shown below. 21
The film must then come together in the vertical sealing rollers Film The film must be fed downwards into the horizontal sealer and vertical preform cutters and then downwards into the horizontal cutter and through the guide rollers Vertical Sealers Sealersers Horizontal Sealers Preform Cutters Perforation cutter Horizontal Knife There must be a line up between your front and back film prints. Setting up of this print must be adjusted on the roller as shown Note: If the film is threaded while the sealing rollers are hot, This will cause burn to the operator. Not film should be threaded through the machine while the rollers are cold. The film must not be allowed to fold or bend during operation causing the underside of the film to be exposed to the sealing jaws. 22
3.3.2 Horizontal Sealing roller adjustment The horizontal rollers are fixed in position and the only adjustment possible is the film pressure. The rollers have adjustment screws as shown Adjustment screws Adjustment screws The horizontal sealing rollers are adjusted only to ensure pressure on the film for sealing purposes. The sealing rollers must have equal pressure on the left and right hand side of the vertical sealing roller. Incorrect pressure adjustment will result in either no seal pressure or too much seal pressure. Both these scenarios must be avoided. Clockwise adjustment of the pressure screws will result in more pressure on the film and anti- clockwise adjustment will result in less pressure on the film. Note: Equal adjustment on the left and right must be adhered to. Damage to the sealing rollers can result from incorrect pressure adjustment. 3.3.3 Vertical sealing roller adjustment The vertical sealing rollers are adjusted only to ensure pressure on the film for sealing purposes. The sealing rollers must have equal pressure on the left and right hand side of the vertical sealing roller. Incorrect pressure adjustment will result in either no seal pressure or too much seal pressure. Both these scenarios must be avoided. Clockwise adjustment of the pressure screws will result in more pressure on the film and anti- clockwise adjustment will result in less pressure on the film. Note: Equal adjustment on the left and right must be adhered to. Damage to the sealing rollers can result from incorrect pressure adjustment. 23
Loosening the adjustment bolts will move each jaw backwards and forwards towards or away from the film. Adjustment screws When the machine is running the vertical sealing rollers should be compressed (engaged) to ensure the right pressure for good sealing, the handle should be at the downwards position as shown. If machine is stopped for a long time or switched off the handle should be lifted as shown. Move handle upwards to disengage the vertical sealing rollers Move handle downwards to engage the vertical sealing rollers 3.3.4 Funnels adjustment The funnels can be adjusted on the funnel holder plate, it can be moved relative to the vertical sealing jaws as well as moved left or right as shown below. Untighten the screw and move the former holder to t right or to the left 24
Keep the funnels clean after extended running to avoid the glue sticking to the funnels which will impact on sealing. 3.3.5 Vertical slitting knives adjustment Adjustment Screws The vertical slitting knives must be adjusted to suit the specific artwork of the film. Left and right adjustment can be achieved by loosening the screws as shown and re- aligning the knives to the correct position 3.3.6 Funnels Removal 1. Open the buckle. Toggle or buckle 25
2. Undo the Locking Knob Lift the plate to disengage the augers from the funnels Knob 3. 3. Loosen the bolts of funnel holder and move the funnel holder to the side to make space to take the funnels out without any damage and bending. DO NOT FORCE! NOTES: Any mishandling of the funnel can cause the funnel to be bent, this will result in the film being misaligned through the vertical sealing rollers and will result in miss tracking of the film. This problem can only be rectified by replacement of the necessary funnel. Trying to align a single funnel once bent will not be successful. 4. Removal of the funnels 26
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3.3.7 Filling volume adjustment The filling system on this model is adjusted via the computer program. See section 3 for details. Setting up the volume Volume: Default value = 0 R- min This value can be set between 1 and 9 (001-1000) and the value represents the speed of the augur turning. The speed depends on the fluidity of the powder. Set key: Preset: Default value = 0 Vol. This value can be set between 1.00 and 9.00 and the value represents the volume of the augur feeding. The number of turns represents the volume of powder delivered. 3.3.8 Cutting system adjustment The position of the cutting knife cannot be adjusted: the position of the registration mark relative to the cutting position can be adjusted. Therefore, move the eye forwards 28
and backwards along the film to produce an earlier cut or later cut relative to the cut position required. When the machine is not set up as eye mark Registration mode. The position of the cutting is not registered and only the bag length can be set. See section 3 for bag length control. 3.3.9 Eye mark registration adjustment If the bag is not cutting at the proper position, turn the red knob on the eye bracket to move the eye forwards and back words along the film. Or check the light on the photocell, if it is flashing all the time, please turn the knob on the eye to adjust the sensitivity. Note: When adjusting the film edge for alignment this adjustment might result in the eye mark registration no longer being in line with the eye. Re- adjust the eye for correct alignment. 29
Chapter 4 Malfunctions (Faults) and their rectification Fault Always check the alarm screen for servo fault Check Servo Motors Communication fault table Status 0 = no fault Machines will not switch on Rectification See Alarm Screen for Servo faults and reset Check power supply to machine Check main isolator is in a reset position Check emergency stop is not pushed (turned) Machine is on, but the machine will not run Machine is on and vertical sealing rollers run but stops soon after Have you pushed the Start push button Check for Vertical Sealing Rollers Servo Drive for faults - Rectify See servo fault page for servo error. If problem persists reset machine power or push reset on touch screen Check Production Speed is set above zero Check to see if the computer is set to length or eye control, if eye check to see eye sensor is functioning. (red LED is lit) also check that registration eye is set to pick up eye mark. Also check to see that registration eye picks up only one eye mark per sachet length. Set registration eye contrast if necessary. Does the film have a registration mark on it and the photo sensor must recognize the mark. Check alignment of the mark to the photo electric eye. If computer is set to length control, does the bag length have a value greater than zero. Some other items to check Is Bag Feed on If machine will still not run 30 Jog machine using the jog button on the front panel. If machine runs then the electrical system is functioning and the operator inputs are set incorrectly Failing this call an IMC Technician
Vertical Sealing Rollers manual test button NOTE: Machine must be stopped and powdered on: Then the manual test function can be operated. Horizontal sealing rollers will not run. Check for Horizontal sealing Servo Drive for faults - Rectify See servo fault page for servo error. If problem persists reset machine power or push reset on touch screen Check Production Speed is set above zero Is sealing position set above zero Horizontal Sealing Rollers manual test button Are vertical sealing rollers running if not refer to fault finding vertical sealing rollers. NOTE: Machine must be stopped and powdered on: Then the manual test function can be operated. Cutting blades will not run. Is Cutter on. Cutting blades manual test button Check for cutting blades Servo Drive for faults - Rectify See servo fault page for servo error. If problem persists reset machine power or push reset on touch screen Check Production Speed is set above zero Are vertical sealing rollers running if not refer to fault finding vertical sealing rollers. NOTE: Machine must be stopped and powdered on: Then the manual test function can be operated. After a jam use Anti- clockwise Perforation rollers will not run. 31 Is perforation rollers on.
Cutting blades manual test button Check for perforation rollers Servo Drive for faults - Rectify See servo fault page for servo error. If problem persists reset machine power or push reset on touch screen Check Production Speed is set above zero Are vertical sealing rollers running if not refer to fault finding vertical sealing rollers. NOTE: Machine must be stopped and powdered on: Then the manual test function can be operated. Draw down rollers will not run. Draw down rollers are connected mechanically to the perforation rollers, check chain and mechanical drive system. Is perforation rollers on. Perforation roller must be on for draw down rollers to function. Check for perforation rollers Servo Drive for faults - Rectify See servo fault page for servo error. If problem persists reset machine power or push reset on touch screen Check Production Speed is set above zero Are vertical sealing rollers running if not refer to fault finding vertical sealing rollers. Film Running but system does not fill product. Is bag fill on. Check for Augur Servo Drive for faults - Rectify See servo fault page for servo error. If problem persists reset machine power or push reset on touch screen Check servo communication screen for communication faults. All should be zero. If communication status is not 0 then 32
communication faults exist. Drivers address parameters could be incorrect or cables could have come loose. Incorrect placement of augur communication cables can and will result in bad communication. Augur servo drives are connected top plug to next augur bottom plug etc. Check that the augurs have fill volumes above zero Check augur is in run mode. If no fill takes place after setting stop machine and test augurs individually manually Make sure all augurs have values inside them. Ensure augur is switched on. Press manual augur run. (all augurs have a manual button) Check manual augur rotation setting is above zero If augurs still don t run augurs could be jammed up. Try reversing augur rotation for manual test. NOTE: Horizontal sealing rollers do not heat up Augurs might require stripping out to release jam up. Are augurs plugged in. Is temperature function on. 33 Are Horizontal temperature controllers on and
Vertical sealing rollers do not heat up not showing any faults. Is the set temperature set above zero Is the actual temperature reading correctly. Is the temperature still not going up even though the temperature set point is high. Check wiring of Horizontal Heaters. NOTE: Horizontal heaters are fed through slip rings - make sure slip rings are clean and making good contact. If not call a IMC Technician Is temperature function on. Horizontal art work miss- match Are Vertical temperature controllers on and not showing any faults. Is the set temperature set above zero Is the actual temperature reading correctly. Is the temperature still not going up even though the temperature set point is high. Check wiring of Horizontal Heaters. NOTE: Vertical heaters are fed through slip rings - make sure slip rings are clean and making good contact. If not call a IMC Technician Adjustment of the film: left and right to be adjusted to advance or retard film. Vertical sealing miss match Adjustment screw above will when screwed clockwise retard the film on that side of the machine likewise clockwise will advance the film on that side of the machine. NOTE: Both screws on each side to be adjusted together (ie same number of turns) otherwise misalignment of the film will result. The film will enter the vertical sealing rollers skew. Definition: The film once it has passed down through the vertical sealing rollers should be equal on both sides, ie. the edge of the front film and the edge of the back film should be aligned. 34
Blade rotating but does not cut Alignment of the film through the rollers for a perfect edge should take place by adjusting the separation plate. (more info) Replace blade if blunt. Set blade position setting to give a good cut. (blades can be adjusted closer to each other) Augurs operating but does not fill Check augurs are on. Check bag fill is on Check volume adjustment is above zero Check augur speed is above zero Check augurs are not jammed Check main hopper has sufficient product 35 See Hopper not filling insufficient product
Hopper not filling Is there product in the hopper. Check product sensor for correct operation Check hopper fill is on Turn on Mixer Turn on Stirrer Film roll not feeding/turning Check film is not finished Check film feed sensors are operating. Registration Eye not functioning Film not sealing - vertically Film not sealing - horizontally Check that registration eye is plugged in and on Check that registration eye has been set correctly for the eye mark contrast. (registration eye must blink from eye mark to no eye mark) Check that registration eye is in the correct path of the registration mark Check that eye is suffiently close but not touching the film Check temperature controllers for correct sealing temperature +- 150 c Check for correct vertical pressure on sealing rollers, (check for good imprint of seal pattern) Check that rollers are hot as indicated if not call technician. Check that no powder dust is in the seal area Check temperature controllers for correct sealing 36
Cutting on incorrect position - horizontally temperature +- 150 c Check for correct horizontal pressure on sealing rollers, (check for good imprint of seal pattern) Check that rollers are hot as indicated if not call technician. Check that no powder is in the seal area Adjust cutting position on Touch Screen Move registration eye forward or backwards in relation to film on registration eye bracket. (After adjusting the eye, you will need to reset the horizontal seal position on the Touch Screen) Product in seal area horizontal (restricting seal ability of sachet) Adjust drop time on Augur start on Touch Screen Filling to start just after horizontal sealing rollers close on sachet. Too much product in sachet Machine running too fast for product to fall into sachet reduce machine speed or speed up augurs Increase augur speed 37
Chapter 5 Operation steps and Maintenance Instructions 5.1 Operation steps 1- switch on machine, check if the temperatures are proper, check if the sealing parts are clean, check if the vertical sealer is at the proper position 2- when temperatures reach, start machine, but Bag fill off. 3- after several bags made, check if the empty bags are nice, please press Bag fill on to fill the powder. 4- when you want to stop machine, please first press Bag fill on to Bag fill off to stop powder filling. 5- after 5 or 6 bags falling, stop machine and lift the vertical sealing handle to make vertical sealer separate during the break. 6- shake the funnels one by one to make sure the funnel empty 7- switch off after daily production. And do the cleaning. 5.2 maintenance instructions 1- before and after machine running, please keep machine clean 2- during machine running, please suck the dust on machine at anytime 3- please keep sealer clean, no glue on it 4- If auger is stuck, please stop machine immediately, and take out the spreading plate, clean the auger 5- take off the funnel and clean in regular time 6- clean the small mirror on photocell in regular time 7- lubricate oil to gear part and bearing in regular time 38
Chapter 6 6.1 List of main mechanical parts 39
6.2 List of Main Electrical Parts No. Main parts 1 PLC1 and PLC2 2 Relays 24v dc 3 Connector Strip 4 Solid relays Heaters 5 Power Supply 6 A.C contactor 7 A.C contactor 8 Circuit breaker Servo motor external plug connections: Ensure all servo motors are plugged in as well as there power systems. During fault finding you can swop two drives plugs around as a fault finding to see if the fault lies with the drive or the motor. Please swop back the plugs once the problem has been found. 40
Main Servo motor Drives: No. Servo drives 1 Vertical Sealing servo drive 2 Horizontal Sealing Servo drive 3 Perforation Cutter Servo drive 4 Vertical Cutter Servo drive 5 Horizontal Cutter Servo Drive Augur Servo motor Drives: Augur Servo Drives 1 Augur Servo Drive 1 of 4 2 Augur Servo Drive 2 of 4 3 Augur Servo Drive 3 of 4 4 Augur Servo Drive 4 of 4 41
List of sensors No. Sensors Location left side of film feeding frame 1 Film Feed Stop Sensor 2 Film Feed Start Sensor 3 Film Finished alarm Sensor Location left side of rear machine case under the film feeding frame 4 Film Frame Left Sensor 5 Film Frame Right Sensor Location Situated inside machine case, left side of servo motors 6 Horizontal sealing position Sensor 7 Perforation cutter Sensor 8 Horizontal cutter Sensor 42
Chapter 7 7.1 Electrical Diagrams 43
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Chapter 8 8.1 Temperature Controllers Supplier XMT-1000 INTELLIGENT DIGITAL DISPLAY TEMPERATURE CONTROLLER INSTRUCTION MANUAL Before using this product, please carefully read this manual for its correct use. In addition, after reading the manual keep it available easily anytime. OPERATION PRECAUTIONS Before cleaning the instrument, check that the power is turned off. Remove stains on the display unit using a soft cloth or tissue paper. As the display unit is easily scratched, do not scrub or touch it with a hard object. Do not operate the front key with a pointed object such as a ballpoint pen or screwdriver, as this may scratch or damage the key. 1. PRODUCT CHECK XMT - 1 234567 8 9 1Panel Dimensions(mm) 5Type of Input D:96 96 1: Thermocouple signal E:72 72 2: Thermo- resistance signal (RTD input) F:96 48(Vertical form) 6Type of Output G:48 48 No: Relay contact (Maximum 3A) 2Type of Display V: Logic output for SSR 1: Double rows display A: Relay contact (Maximum 16A) 3Type of control action G: Relay contact (Maximum 16A) 0: On- off action Relay 7Type of power 3: Time proportion action X:20~40v; Y:187~242VAC; Z:85~264VAC 4: On- off PID control with auto tuning 8Type of calibration 7: Single phase zero- across pulse PID action with auto- tuning 9The range of measurement <Accessories> 4On- off position Alarm Mounting bracket: 2 pieces 0: No alarm Instruction manual: 1 copy 1: High alarm 2:absolute value of high 3:Low alarm 4:absolute value of Low 2. MOUNTING 2.1 Main technique principal (1) Type of Input: thermocouple E, EA, K; thermo- resistance Pt100, Cu50. (2) Measure the error: ±0. 5%(F,S)±1di g (3)Measure temperature at most: 999. (4)Control method: On- off action Relay,Time proportion action,single phase zero- across pulse PID action with auto- tuning (5)P I D Choose the range in parameter: Proportional band 1~100%, Integral time 0~999s, Differential time0~999s. (6) The time of keepi ng t i me: t en year s. (7)Control the capacity of outputting: Contact type:3a/250vac(resistance load), Life- span of contact 10^5times; Level type(used for driving SSR or controlling the logical circuit): 12VDC/30Ma; SSR(Used for urging SSR to use for driving the two- way silicon controlled rectifier of high- power): 0.5A/250VAC. (8) Alarmoutput: Contact type, Capacity of contact:1a/250vac((resistance load). (9) Great power output type: Contact type: 5A/250VAC. Pulse type: 2.5A/250VAC(XMTG TYPE),4A/250VAC. (10) Voltage of the power: Consulting type table power range. (11) Consumption: 5W. (12) Environment for use: Temperature 0~50, Ambient humidity 85%,Has not corroded, there is no conductive dust 3. Configuration of the Instrument Panel 52
1Measured value (PV)display unit (Red) Displays measured value (PV). PV Displays various characters depending on the instrument. 1 2Set value (SV)display unit (Green) Displays set value (SV) SP 2 Displays various each parameter set value depending on the instrument. 3Indication lamps ALM OUT AT 3 Auto- tuning(at)lamp [Green]. Flashes during auto- tuning execution. Control output lamps [Green](OUT)turned on when outputs operate SET AT Alarm output lamp (ALM)[Red] turned on when output operate 4 Function key Used for displaying the change and confirm of the 4 5 6 7 parameters 5 Shift Key Used for Adjusting key to change the digital code and/or the key to express entering the auto- tuning state 6,7 Adjusting key to change the digital. Used for adjusting the digital code displayed 4. Dimensions H h The appearance and the hole measurement form: B L b b h type Size of the panel H B Size of the shell h b L the size of hole h b XMTD 96 96 92 92 70 (92+1) (92+1) XMTE 72 72 68 68 70 (68+1) (68+1) XMTF 96 48 92 44 70 (92+1) (44+1) XMTG 48 48 44 44 70 (44+1) (44+1) 5. Wiring 5.1 Wiring attention (1) The electric thermocouple inputting, should use the corresponding compensation wire. (2) The input signal line should be far away from the instrument cable, motive force cable and load line, in order to avoid producing the miscellaneous news to interfere. 53
6. Operation 6.1 Have the electricity to show: Belonging to the display and indicator lamp to light after being set up an electric circuit, then show the type and graduation number, then upper and lower limit Cheng of showing etc., the first three status display enter routine measurement value after the one second respectively / the establishing value show that put into and control running. PV On power SV All displays lighting The type of the instrument and calibration The range of measurement Measureing and establishing value display Caution: The calibration code of the instrument inputing : E: Thermocouple, K: Thermocouple, EA2: Thermocouple CU50: Thermo- resistance PT100: Thermo- resistance 6.2 Establish temperature value: Press or 5 6 both can enter the state of establishing, If below row displays " SP " ( establishing value code ); Press 5 6 can add and subtract the temperature of establishing one by one: Press 5/AT can select figure number revised to want, make it glimmer, press 5 6 can make it glimmer location choose a number value needed from 0 to 9 After modifying the establishing value, press a key approve and withdraw the setting for value not to set for the state to revise the method of establishing negative temperature: Establish temperature value first, press 5/AT establish high position most, press 6 make it reduce to " 0 ",continue according to appear" - "Number 6.3 P I D parameter Auto- tuning After the machine is set up an electric circuit, establish temperature at first, press 5/AT greater than ten seconds, " AT " indicator lamp show instrument enter course of auto- turning, after two shake cycle system to glimmer, the auto- turning ends, " AT" light put out, instrument at this moment get one control parameter that group optimizes and keep for a long time. CAUTION: 1 When the systematic operating mode changes bigger, should since exactly fix once again, in order to meet the new systematic parameter 2 it will withdraw from the state of auto- turning while losing electrical power,it s parameter does not change Following table lists the function parameters The first step The second step: Show each parameter in the order with pressing If revise the shown parameters,please press 5/AT and select figure number that will be revised, and make it glimmer, press 5 6 can change to glimmer in the location. Press to confirm and keep after finishing revising Press + 6 10s can enter the state of establishing parameter Orde Type of Represent the Number value meaning r Display content 1 2 Db: Difference switched over Ub: The time proportion is established again 3 Proportional Band 4 Integral Time 5 Differential Time 6 Control Period 7 Control mode 8 Warning value of upper limit, the warning value of lower limit, the warning value of the 54 Dead band for on- off control and Alarm. For on- off controller, On- off control and alarm adopted Same value. The time proportion is established again, dispel the quiet and bad power of maintaining(0~90%).only used for adjusting the quiet difference of the proportion controller When P is large, the proportional Action is small. Only used for heating Side. P=0,On- off Control (Re- setting time) When I is large, the integral action Is small. I=0,PD Control (Pre- setting) When D is large the derivative Action in large. D=0,PI Control 1 Contact type:the electric heater of general machinery is fetched for 20-30 seconds, Fetch the large capacity oven heater for 30-120 seconds 2 Contactless type:fetch for 3-10 seconds Ctr=0/4; Routine control; Ctr=1/5; avoid high shoot; Ctr=2/6: have cable avoid overshoot only, later controlled according to routine PID Ctr=0~2 is AH or AL; Ctr=4~6 is AE Initial value setting at factory 0.5 5% 15.0 180 70 20s 4s 2 Lower limit of the span/ Upper limit of the span
deviation 9 Amplitude limiting of establishing value establishing value SA Lower limit of the span 10 The sensor revising 11 Set data Lock Revise the error of the sensor, revise the range as 0-12.7 Lck fetches 123, the parameter can be changed, then the parameter can't be revised to fetch other value. 0 1234 The third step Press and withdraw from the state of establishing parameter 55
8.2 Servo Driver Manual 56
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8.3 Servo Drive Parameter setting list Auger servo drive parameters 61
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Main servo drive parameters 63
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8.4 Pneumatic vacuum charging machine 1. Principles Of Operation Vacuum charging machine is a vacuum conveyor that takes pneumatic vacuum pump as the vacuum sources. With this vacuum charging machine materials can be directly transferred into mixer. Reactor, hopper, performing machine, packer, vibrating screen, straightening granulator, wet type granulator, dry type granulator and grinder from containers. With this machine, labor intensity of workers is reduced and dust pollution is prevented, which makes the production meet the GMP requirement. When you press the on- off key, compressed air enter into the vacuum pump, and at the same time driven by the cylinder, emptying door of hopper is closed and then vacuum is generated in the hopper. Under the vacuum, one stream of airflow is formed in the vacuum charging machine. Under the effect of this airflow, materials are transferred into the vacuum hopper through hoses, after a certain time (charging time, adjustable), compressed air is closed. Vacuum cannot be generated in the pneumatic vacuum pump. And in the mean tine driven by the cylinder, emptying door of hopper is opened; vacuum disappears in the vacuum charging machine, materials are emptied into the charging equipment (such as performing machine, packer and etc. ) automatically from the emptying door and at the same time, compressed air in the air bag blow back the filter, and the filter is cleaned automatically; after a certain time (charging time, adjustable) compressed air is reset, vacuum is generated in the pneumatic vacuum pump, the emptying door is closed, vacuum charging machine charge again, moving in cycles, materials are transferred into the charging equipment continuously. For the level- controlled vacuum charging machine, materials in the hopper of charging equipment are charged automatically through level controller, when hopper of charging equipment is higher than a position, vacuum charging machine will stop charging; when hopper of charging equipment is lower than a position, vacuum charging machine is reset automatically, materials are charged in the charging equipment.. pneumatic vacuum pump filter tube control box vacuum hopper access of compressed air connecting and absorbing hose emptying door 66
1.1.Technical indicators type Quantity conveyed Air consumption Air pressure (kg/h) (liter/min) (mpa) QVC- 1 350 180 0.6 QVC- 2 700 360 0.6 QVC- 3 1500 720 0.6 QVC- 4 3000 1440 0.6 QVC- 5 5000 2880 0.6 QVC- 6 6000 4320 0.6 1. compressed air should be oil- free and water- free. 2. conveying capacity is measured at the three meters of conveying distance. 3. there is big difference in conveying capacity for different materials. 1.2 Debugging and installation 1. Vacuum hopper is fixed on the hopper of performing machine and packer (or other equipment) through catch ring. for the hoppers of charging equipment that the vacuum hopper is unable to fix on them.holder could be made to fix the vacuum hopper 2. When control box is delivered from the factory, it is hung on the vacuum hopper During the installation,based on the operating conditions, workers can hang it on anywhere. 3. Connecting of compressed air tube: A. Selection of tube diameter for compressed air access (I.e. the room for installation equipment). For QVC- 1, 2, 3, select 1/2 tube For QVC- 4, 5, 6, select 3/4tube For QVC- 1 vacuum charging machine, it should select Φ10pu tube. B. After the operation of compressed air access, it should install ball valves and air pressure regulator- filter. For type selection, please refer to figure lll. C. For QVC- 1,2 vacuum charging machines, exit of air pressure regulator- filer should be connected with the compressed air entrance joint below the control box.diameter of compressed air tube should be consistent with the compressed air entrance joint below the control box. D. For QVC- 3,4,5,6 vacuum charging machines, exit of air pressure regulator- filer should be connected with the compressed air entrance joint on the vacuum generator.diameter of compressed air tube should be consistent with the compressed air entrance joint on the vacuum generator. E. It should connect the compressed air tube between control box and vacuum generator in accordance with fig ll and fig lll. 4. The AC 220V plug is plugged into the power seat,if the time indicator on the control box displays,it means the power has been accessed to the system.it should be noted the power cord must be three lines,control cabinet should be connected with the ground to avoid computer chip is interfered and the system is crashed. For connecting diagram of control box, please see Fig vl. 5. Change key of time- touch, charging time is adjusted in 5-15 second, emptying time is adjusted in 6-12 second.when the powder material is conveyed,the charging time should be 67
set for a short time while the emptying time should be set for longer time,when the pellet material is conveyed,it is just the opposite. 6. Press the on- off key, compressed air will be conveyed into vacuum generator, vacuum is generated in the vacuum hopper, and charging is operated. 7. Now pressure of compressed air should be noted, air pressure should be 0.6Mpa. Air pressure is the pressure of compressed air in the system during the running of vacuum generator, i.e. during the charging time. There is manometer on the vacuum generator of QVC- 3, 4, 5, 6 vacuum charging machines and the pressure is based on the display of the manometer. For QVC- 1, 2 there is no manometer on the vacuum generator, the pressure is based on the manometer of air pressure regulator- filter. During the debugging, it should be specially noted air pressure 0.6Mpa is the air pressure during the charging. During the emptying time or the system is in standby state, pressure on the manometer of air pressure regulator filter should be 0.7-0.8Mpa, when many users install the changing machine, they often adjust the air pressure regulator filter at 0.6Mpa. Now if vacuum generator start to work, pressure of system will be decreased at 0.4Mpa which will be fail to charging or unable to meet the charging requirement. For the long distance conveying or large conveying capacity, air pressure in the system should be reach 0.6Mpa. 1.3 Fault Resolution If the charging machine cannot word or charging capacity is decreased, please check it in accord once with the following procedures. 1. If the air pressure in the system is reached 0.6Mpa. Air pressure is the air pressure in the system during the work of vacuum generator. 2. If the emptying door is closed tightly. A. After long time use, much powder material is piled at the emptying door so that the emptying door cannot be closed tightly.so the emptying door should be cleaned. B. After long use, sealing of emptying door is worn so that the emptying door cannot be closed tightly. So the sealing should be changed. C. After long Use there is trouble for cylinder output and stroke,so the cylinder should be changed. 3. Filter plugging. After the filter is blew clean by compressed air, blow back the filter with mouth if it is very flow, it means there is no obstruction in the filter, if it feels suffocated, it means the filter is blocked; now the filter should be changed or cleaned in the ultrasonic cleaning machine for over 30 minutes. 4. Suction tube is blocked by big obstruction. This condition often occurs at the entrance of stainless steel suction mouth and the entrance of vacuum hopper. 5. The clamps between pump head and hopper, among hopper are not screwed tightly. So the air is leaked is the system, so materials cannot be charged or charging capacity is decreased. 6. There is trouble is the system blow back. For every emptying of the vacuum charging machine, the compressed air stored in the air bag blow back the filter, it should guarantee there is only on layer of powder on the surface of filter, if should guarantee there is only on layer of powder on the surface of filter. If there is trouble for the blow back system, much powder will be piled on the surface of filter, the resistance will be increased. So the materials cannot be charged for the vacuum charging machine, now the blow back valve should be changed. 68
1.4 Cleaning For the difference of change type or batch number in the pharmaceutical factory. Vacuum charging machine should be often cleaned. It has been considered fully in the pneumatic vacuum charging machine, so the following items need to be noted during the cleaning; 1. Release the hasp; remove the pneumatic vacuum pump modules. Pneumatic vacuum pump, air bag and cover are connected into one, so it doesn t need to be cleaned with water. 2. Remove the filter modules, blow the powder on the filter tube clean with compressed air and then washing repeatedly with hot water, after it is clean, the water in the filter tube, wall should be blew clean with compressed air. Now if you blow back the filter tube. It should be flow, if you feel suffocated; it means there is water in the filter tube wall. It needs to be blown clean with compressed air and then be dried by air or by heat. 3. Release the catch ring, remove the vacuum hopper, and clean it with water. 69
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8.5 Multihead Ink Roll Coder Preface 1. Please read the instruction before using the machine. Take all reasonable security precautions in the use of machine to avoid possible harm. Always take care to ensure no rotation, no displacement, no dumping, especially when the floor is damp or oil- polluted. 2. Installation and repair should be done by trained workman. When electricity leak occurs, a qualified electrician must be required to do a comprehensive electrical installation, inspection. 3. Never dismount the machine when it is running. Before dismounting, turn off power supply switch. 4. Earth wire should be well earthed to ensure personal safety. 5. Heating unit and character types holders are of high temperature, Do not touch the heater when doing heating to avoid the scalding. Turn off the power, wait for cooling before maintenance. 6. Never place any inflammable material such as cloth, wire and plastic etc on the heating unit, to avoid accidents. 7. Don t impact the character. Don t fold power wire, signal wire and control wire. 8. All cables should be connected without power supply and then can turn on power switch. Ⅰ. Main Structure 72
Ⅱ. Performance and Technical Parameters NY- 808E multi- head ink roll coder is applicable to horizontal continuous packing machines to print production date, lot number, price and weight on any soft packaging material such as plastic film, PP, OPP, paper bags, label, leather and so on. The printer is mainly made up of printing mechanism, step motor, bracket, heating device, preheating device and control box. It adopts electronic circuitry which can control the temperature and the position automatically. And the pressure, position, temperature and shade of printed characters can be adjusted during the process of printing. It is driven by the stepping motor, which can do the printing work with the same speed as the master machine. It is widely used in the industries of foodstuff, beverage, and pharmaceuticals etc. Technical Parameters Driver Print Speed Power Supply Stepping Motor 0-300 times/min Single Phase AC220V/50Hz 850W Font Size 2 3.4 7.2; 3.4 3.4 7.2 Dimension Weight Consumable 560mm 195mm 240mm 15kg Ink roll φ35 30mm Ⅲ. Description of Control System 73
Power Supply ON/OFF: Power switch of control box. Foreward /Reverse: The output power adjusted by setting the electric current of driver and the printing direction of leftwards or rightwards can be adjusted by the forward and reverse button. Temperature Ink roll temperature: The data on the screen of temperature control box means ink roll temperature. We can adjust the temperature through direction button to get reasonable temperature. Normal temperature is 120. Character temperature: Normally set the position at 2.5, the scale refers to actual temperature as shown below: Scale 0 1 2 3 4 5 6 Temp. 0 42 68 92 116 140 164 Test Button: In case that coding machine fails to work when other wires are properly connected, turn on the test button with the work button off, there is encoder rotary installed onto printing rubber roller, let the rubber roller run by hand, if the test indication lamp is shining, it can be sure that machine is under good condition, the reason is that signal wire is damaged or there is no signal input. Work Button: Turn on work button, indication lamp will lighten red, and coding machine begins print, synchronously with the input speed of signal. Place Button: When packing speed is fast, we adjust the place from 0 to 9; each scale corresponds to printing position change more. So if packing speed is fast, we need turn down the place scale from 9 to 0; or the print result will be affected. The place scale corresponds to actual delay time as shown below: Place: 0 1 2 3 4 5 6 Delay time: 0 0.02 0.04 0.06 0.08 0.10 0.12 74
Wire Pin Function Instruction 2P: Power Input 2A: Fuse 3P: Signal Start- up Input 1positive electricity + ; 2signal start- up; 3negative electricity -. 4P: 1thermocouple + 2thermocouple - 34heating. 5P: 1proximity switch and test 12V; 2test signal; 3blank; 4proximity switch stopping signal; 5ground wire for proximity switch and test. 6P: 1stepper motor A+; 2stepper motor A- ; 3stepper motor B+; 4stepper motor B- ; 56heating. Ⅳ. How to Set up Print Position Vertical Position: the transportation direction along the packing films means vertical position; Al is the datum mark before adjusting. The change of the position 0-9 will be remarkable with the increase of packing speed after adjusting. So we should adjust downwards the display of writing 0-9 when the packing speed is too high, otherwise the writing effect would be influenced. Horizontal position: The adjusting of horizontal position could be achieved by loosening the screws first, moving print head to the proper position and then tightening the screw. Ⅴ. How to Replace Ink Roller Take out the ink roll arbor [refer to the Fig5], and then fetch out the ink roll, replace with the new ink roll. You need 5 minutes preheat the ink wheel and let it soften, in order to make the machine running again. 75
Ⅵ. How to Load and Replace Characters Demount the end cap of characters and the characters, install the new characters, then use end cap for characters. Ⅶ. How to Adjust Font Clearness Turn the ink roller adjusting screw of ink roll fixing structure to make ink roller moving up and down, thus to adjust the contact between printer roller and ink roller, and to make the type face of printer roller 0.05-0.10mm into the surface of ink roller. Keep printing clear, but not too close, as it may damage the ink roller. Turn the screw rightwards, and the ink roll will close up to the character interface. So after a period of use time, adjust the ink roll downwards, until there is no ink. Make notices that every time you replace the ink roll, please adjust to the initial state, to enable effective use of ink wheel. 76
Ⅷ. How to be Installed onto Packing Machine Install the coding machine onto the platform of packing machine, keep the rubber roller of coding machine paralleled with that of packing machine, then fasten mounting screws. Install the control box of coding machine, put in and fasten the outfitted special connecting cable for coding machine, connect the synchronous signal input line to the normally open contact of the limit switch on packing machine (proximity switch available), then connect AC200V power line. Synchronous Control Installation Diagram 77
Wearing the Film Ⅸ. Common Failures, Causes and Solutions Problem: Reason: Solution: 1.Character can t be printed out A. The temperature isn't high enough B. Ink roller isn't in or the character isn't in C. Ink roller is too high or the pressure isn't enough D. Ink roller doesn't touch the character grains in the printing roller A. Prolong the warm-up preheating time, increase the temperature, change the bad heating tube, change circuit board B. Put it back quickly and operate again until warm-up C. Adjust the pressure of printing roller and keep it even D. Adjust the distance between 2.The character is too dark 3.the printed character is totally vague or partly vague 4.the action of printing head isn't flexible or the printing head can not move 5.printing head keep rotating without break 6.the damage of packing materials 7.other problems A. The pressure of ink roller is too high B. The temperature is too high C. The distance between the ink roller and the printing head is too small A. The character grains are uneven B. Improper adjusting of the level of ink roller C. Ink roller is too old A. Input breakdown of course switch signal B. Breakdown of circuit board C. Breakdown of velometer A. The swing hinge of the claw of the clutch is loosened or isn't lubricant B. breakdowns of the circuit board A. The temperature is too high B. The pressure is too high A. improper operations B. The abrasion or looseness of machine parts. C. The aging of the components of the circuit board 78 the ink roller and printing head A. Decrease the pressure B. Decrease the temperature properly C. Increase the distance between them A.even out or change the character grains B.Readjust C.Change a new ink roller A. Repair or change the course switch B. Repair or change the circuit board C. Change or adjust the velometer A. Tighten and add the grease B. Repair or change the circuit board A. Low temperature of thin material, high temperature for thick material. B. Adjust the ink roll upwards to lessen the pressure meanwhile keep the printout clear. A. Reread this manual B. Change or tighten the machine part C. Keep maintenance and repair regularly
Ⅹ. Description of Circuit Theory Ⅺ. General Maintenance 1. Always keep the equipment clean. Clean once a continuous working day with absolute alcohol for printer roller, copper characters and the heating unit of ink roller. 2. Clean up the dust and dirt every time when we change the metal types in order to keep the surface of the character neat. So we can get the ideal effect of the printing. 3. Regularly check the screws on frame head and bracket to avoid looseness. All metal transmission components in the transmission box should be kept lubricant and should be appended lube. 79
Ⅻ. Accessory List Name Specifications Quantity (Piece) Operation Manual 1 Ink Roll φ35*30 2 Characters 1 set Heating Tube φ9.5*35 2 Fuse 2 Proximity Switch 1 4P Connect Wire 5P Connect Wire 1 6P Connect Wire 1 Power Wire 1 Control Box 1 80
Chapter 9 9.1 Spare parts list No Part name Photo Usage Model 1 2 Vertical sealing element Horizontal sealing element Seal bag vertically Seal bag horizontally 3 Vertical cutter 4 Horizontal cutters 5 Perforation cutter 6 Temperature sensor Temperature of heater to meter 2 meter length 7 Touch Screen Snasda HMI- 707 Digital Control 8 temperature sealing XMT- 1000 controller temperature 9 Vertical heating tube Give heat for sealing 10 Horizontal heating tube Give heat for sealing 81
11 Speed control motor Film Fame motor 5IK40GN- C 12 Speed control motor Film Feed motor 5IK90A1- CF 13 Speed control motor Starrier motor 5IK90A1- CF 14 Auger servo motor 1-4 auger servo motors Snasda Y1 400W- 60-8 Snasda 15 Auger servo driver 1-4 Servo motor driver SD21A HO 20 80CM 60-400W Horizontal sealing, Vertical 16 Servo motor Servo motor 17 drive sealing, Horizontal cutter, Vertical cutter, Perforation cutter servo motors Horizontal sealing, Vertical sealing, Horizontal cutter, Vertical cutter, Perforation cutter servo drives Snasda M1406-212MN0037 Snasda SD21A HO 20 80CM 750W 82
18 Power supply Snasda 19 PLC1 SD5D- 32MT- DC Snasda 20 PLC2 SD5D- 32MT- DC 21 Solid state relay ZG3NC- 340B 22 Relay JZX- 22F (D)/2Z 23 Circuit breaker Power protection DZ- 158 83
24 AC Contactor CJX2-6511 25 AC Contactor CJX2-1810 26 Magnetic switch GD- TL- Q5MC1 27 Auger and tube 28 Vacuum conveyor 29 Vacuum conveyor 84
30 Pneumatic system 85