SUPER SEALER SUPER SEALER PO Box 92, Avondale Heights, Victoria, Australia 3034 Phone: +61 3 9013 2688, Fax: +61 3 9013 9458 www.supersealer.com.au Updated: 10 October, 2009 Page 1 REF: REI-90-0611
OPERATION & MAINTENANCE MANUAL Model: REI-90F Table Top Gas Flushing Tray Sealing Machine This is a generic operational manual for Model REI-90 Super Sealer Table Top machines and includes some of the other features that may not be applicable for your specific machine. Before operating the Super Sealer Machine, ensure that you thoroughly read this manual first. CAUTION: BURN HAZARD Cleaning and maintenance should be performed by your trained personnel only Allow unit to cool at least 90 minutes before normal cleaning If hot machine must be opened, keep hands away from upper moulds and the printer Routine maintenance or prompt cleaning after a spill will help to maintain the proper performance of the REI-90 tray sealer. Any troubleshooting or repairs other than cleaning must be referred to Super Sealer service center. Please contact Super Sealer Australia on 03 9013 2688 if you have any questions. Updated: 10 October, 2009 Page 2 REF: REI-90-0611
1. Introduction...4 2. Main Parts...4 2.1 Specifications...5 3. Operation...5 4. Control Panel...6 5. Resetting Computer Program...7 6. Roll Film Set-Up...10 7. Date Printer/Coder...10 8. Mould Removal and Replacement...11 6.1 Upper Mould...11 6.2 Lower Mould...12 9. Maintenance and Cleaning...12 9.1 Daily Maintenance...13 9.2 Air Pressure Controller...13 10. Trouble Shooting Guide...13 11. Wiring Diagram...16 Updated: 10 October, 2009 Page 3 REF: REI-90-0611
1. Introduction Super Sealer REI-90F tabletop gas flushing sealing machine models are suitable for films from reel. Ideally suited for small to medium batch operations, new product development, testing and market samples. The machine offers superior quality machine suitable for small and medium food processing factories. Suitable for any sealable cups and trays such as PP, PE, PET, PVC, Card Board or Foil Trays. MAIN FEATURES Up to about 8 cycles per minute Gas Flushing (MAP) Stainless steel SUS 304 frame construction and components are standard Requires pneumatic compressed air supply 2HP (600KPa, 20L/M). Sealing moulds can be exchangeable for different tray for about 5 minutes only. Safety Features gearless construction and safety front panel Container Photo Sensor or Manual option Film Sensor or Encoder option Film Border from 2mm (standard is 4mm) (Pull Tab Option can also be requested) OPTIONALS Options are not a simple plug and play type. The machine s physical construction and the control system are predefined as per customer requirements and specifications. Date Printer/Coder (hot ink manual) Interchangeable Mould Integrated Filling Machine (piston filler) 2. Main Parts 12 11 2 1 3 1. Sealing Film Roll 2. Film Clamp 3. Film Rail Guide/ Clip 4. Eye Mark Sensor 5. Encoder 6. Lower Mould Slider 7. Lower Plate 8. Lower Sealing Mould 9. Upper Sealing Mould 10. Safety Door 11. Control Panel 12. Spring Clip 13. Date Printer (optional) 10 8 9 4 5 6 7 Updated: 10 October, 2009 Page 4 REF: REI-90-0611
2.1 Specifications REI-90F Machine Construction Output Capability Air Requirement Machine Dimension Machine Weight Power Requirement Roll Diameter Roll Width Stainless Steel/ Aluminium Alloy Up to 8 cycles per minute 2HP (600KPa, 20L/M, 80 psig) ~ 430Lmmx660Wmmx710Hmm ~ 80 kg 1Phase, 220-240Vac @ 10Amps 2 inches diameter 280mm diameter Machine Specification is dependent on the size of the container and the machine applications. Cycle time is reduced with the introduction of the gas flushing. MAP Inert Gas Requirement Oxygen Residual Capability Inert Gases 80 psig and 5 scfm Achieved < 2%* Nitrogen, Carbon Dioxide, Oxygen, Noble Gases The oxygen residual capability could be adjustable and is dependent on the container size, the type of product application, flushing dwell time requirements and the gas purity used. 3. Operation a. After connecting the plug to the AC power source, the power indicator light will be turned on. b. When the power on key is pressed, the microcomputer will automatically check if all sensors and switches are functioning. When all are operational, the lower mould will move to the initial eject position. This power on checking procedure will take approximately five seconds. The sealing film system is also checked by the machine control system at all times. c. Once the power has been switched on, the first heating time interval will take approximately five minutes, (this depends on the set temperature, and the environment temperature). After reaching the set temperature, the heating indicator light will switch off automatically. d. The machine can be operated manually or automatically (and this can be set on the control panel). On MANU (manual) mode, the operator needs to press the MANUAL button to perform the sealing function. During AUTO mode, the container photo sensor will be triggered to perform the sealing function. e. During the sealing process, the upper mould is pushed down against the lower mould using a constant air pressure to obtain a fast and even sealing. When the sealing film is heat sealed onto the container, a cutter blade concealed in the upper mould will cut the sealing film to its predefined shape. f. The lower mould will eject automatically after the sealing and cutting function; ready for the next cycle. g. Remove the container after sealing and perform (e). h. To shutdown the machine, turn off by pressing the Power key, and then disconnect the plug to the AC power Updated: 10 October, 2009 Page 5 REF: REI-90-0611
4. Control Panel Image 2. Sample Control Panel The control panel is where some of the functions of the machine could be adjusted and/or modified based on your specific machine requirements. Please note that the machine is delivered with predefined feature parameters and you may not need to change any of the defined settings. POWER ON/ OFF The power on/off switch to start/stop the operation of the machine. Press power Key on to start up the machine. After power on, The counter display will show P0 indicating the machine has started and ready for use TEMPERATURE CONTROL This is to manage the temperature setting in degrees centigrade ( o C). Up and Down: to increase or decrease one unit of value Polypropylene, PVC or PET films could have the default settings of 135 to 220 o C. This will vary based on the type of containers and sealing films used. MOVEMENT CONTROLLER MANU MANUAL OPERATION (Recommended Setting) During manual operation, the machine sealing will be triggered by pressing the MANUAL button AUTO AUTOMATIC During AUTO operation, the machine sealing will be triggered by the container photo sensor. CALCULATOR Display the new reset counting number (from zero) or the accumulated counting figure (from last figure). Press calculator to reset the value to 0 (zero). GAS FLUSH TIMER Allows you to set the gas flushing time in seconds. Updated: 10 October, 2009 Page 6 REF: REI-90-0611
ON OR OFF SELECTIONS The machine will not be performed the function when the setting is set to OFF. FILL RESET Changes the computer operating function. GAS FLUSH Right display: displays the temperature in the normal operation, when an error occurs it shows the error code, and displays parameter values when the machine is under set mode. Up and Down: to increase or decrease one unit of value. Left display: counter number display. It also shows the computer program form P0 TO P11 5. Resetting Computer Program No. Description Range Set in Factory P 1-1 P 1-2 The 1st SET of upper mould heater. The 2nd set of upper mould heater. 030-220 C 030-220 C P Printer heater. 030-220 C 100 1-3 P2 Calculator lock/open Lok: Lock (can t rest) Opn :Open (can set) Opn P3 Sealing time 001~030 unit ( 0.1sec~3 sec) 010 P4 Cup waiting time 000~030 unit ( 0 sec~3 sec) 010 unit (1sec) P5 P6 Rolling film and printer 000(eyemark control and 1st printer or no-printer) P8 or 001(encoder control and 2nd printer) P6 or P7 or P8 or 002(eyemark and 2nd printer) P7 or P8 or 003(encoder and 1st printer or no-printer) P6 or P8 or Non-printed film by encoder control 004~060(non-printed film controlled by timing) P8 or 130 130 001~255 unit (1unit=2mm) 128 P7 The 2nd print position 001~199 unit (0.1~19.9) 52 P8 P9 Printer choice Gas Flush Time 000(stop printing function) 001:moter type of printer (002~030):air type printer 000-100 01 04 10 A. When resetting the computer program: check from P1 to P8 in numerical order. Updated: 10 October, 2009 Page 7 REF: REI-90-0611
B1. Press SET until the left display shows P1-1, the right display shows Temperature in degree celcius of the 1 st set upper mould, press or to set up the new temperature. B2. Press SET until the left display shows P1-2, the right display shows Temperature degree of the 2nd set of upper mould, (this only exists if the have two sets of moulds) push or to set up the new temperature. B3. Press SET until the left display shows P1-3, the right display shows Temperature degree of the printer heater, push or to set up the new temperature. C. Press SET until, the left display shows P2, this represents the counter calculation mode, the right display shows the counting mode, LOC means the counter reset is locked, it will continuously count from the last figure. If OPN is selected, it means the counter reset to zero. The factory setting is OPN. D. Press the SET key until the left display will show P3, and the right display shows sealing time, use, keys to increase or decrease the value by one unit (0.1 second). Generally, the value is assigned between 010 and 020. It is set at 015 at the factory. E. Press the SET key until the left display will show P4, and right display shows the cup waiting time, this indicates the cup will wait for before moving into the sealing position. Use, keys to increase or decrease the value by one unit (0.1 second). Generally, the value is assigned between 005 and 015. It is set at 010 (1 sec) at the factory. (This function based on the whether sealing film is printed or non- printed, and with or without a date printer) F. Setting the film-length for sealing and date printing: (1) Printed film without date printer Press the SET key until the left display shows P5, and set the right display value to 000. This indicates that the film will be controlled by an eye-mark sensor. (2) Printed film with date printer, printing once in a cycle. Press the SET key until the left display shows P5, and set the right display value to 000, indicating the film is controlled by the an eye-mark sensor, press the set key to P8 and choose printer type, the date printer will print the film at the same time when sealing. (3) Printed film and date printer, printing twice in a cycle: Press the SET key until the left display shows P5, and set the right value to 000, Press the set key again till P7; the right display will give a value between 001~199, set the correct value for the distance between the 1st printing and 2nd printing, press the set key to P8 and choose printer type, (The 1st printing is operated with the sealing mould simultaneously). (4) Non-printed film and without date printer Press the SET key until, the left display shows P5, and set the right value to 003. This indicates the film will be controlled by length counter, press the set key until, the left Updated: 10 October, 2009 Page 8 REF: REI-90-0611
display shows P6 and the right display will give a value between 001~255, set the correct value for the length of film to be sealed and cut, press the set key to get P8 and choose printer type. (5) Non-printed film with printer printing once each cycle. Press the SET key until, the left display shows P5, and set the right value to 003.This indicates the film will be controlled by length counter, press the set key until, the left display shows, P6 and the right display will give a value between 001~255, set the correct value for the length of film to be sealed. The printer will print to the film once while the film is sealed, press the set key to P8 and choose printer type. (6) Non-printed film with one printer printing twice in a cycle. Press the SET key until, the left display shows P5, and set the right value to 003, Press the SET key to P6; and the right display will give a value between 001~225, set the correct value for the length of film, then, press the set key, to P7; and the right display will give a value between 001~199, set the correct value for the distance between the 1st printing and 2nd printing, (The 1st printing is operated with the sealing mould simultaneously) press set key to get P8 and choose printer type, G. Press the SET key until, the left display shows P8 in the right display 001 indicates printer mould actuated by motor. 002 indicates printer mould actuated by air cylinder. H. Press the SET key until, the left display shows P9, and set the right value from 000 ~ 100 for gas flushing time setting. ( 000 meant Turn off gas flush function ) I. Press set key until, the left display shows YF, and right display shows LCC, means all set procedures are finished. The left display returns to normal counting, and right display shows the temperature of the heater. As the heater reaches the set temperature, the machine is ready for operation using either the auto mode or manual mode. J. To stop the machine, press the power key once, the left and right displays will turn off, while the power indicator is still on. This indicates the controller is in sleep mode, press power key once to wake it up. To turn off the power indicator, you need to unplug the machine from the electrical socket. Updated: 10 October, 2009 Page 9 REF: REI-90-0611
6. Roll Film Set-Up Setting Up the film roll is a simple step of following the direction as per the images below with printer or without the printer. Wit Date Printer Without the Date Printer 7. Date Printer/Coder Specification Type Manual Hot Ink Stamp Maximum Number of Lines 4 Font / Font Size Times Roman 12 font Ribbon / Ribbon Color 100 meters/ Black (standard) Maximum Number of Alphanumeric per line 9 (e.g. 20060918, EXP060918) Temperature Setting (adjustable) 50-100 C (Default 100) ON/OFF Using the Control Panel Printer Position The position can be adjusted manually The information (e.g. date/time) is manually loaded on the date printer alphanumeric holder. Simply slide in the information on a MIRROR direction. WARNING! The printer uses HIGH temperature to function. Please ensure that you allow the printer to COOL DOWN for at least 90 minutes before changing the printer information. Updated: 10 October, 2009 Page 10 REF: REI-90-0611
Printer Ribbon Setting 8. Mould Removal and Replacement ELECTRICAL HAZARD Always REMOVE the machine from the power outlet before performing any maintenance or cleaning works. BURN HAZARD Cleaning and maintenance should be performed by your trained personnel only Allow unit to cool at least 90 minutes before normal cleaning Always wear hot pad gloves when performing machine cleaning. 6.1 Upper Mould Sealing and Cutting Function Standard Upper mould (i.e. without the gas flushing option) performs the sealing and the cutting function at the same time. Removing and Exchanging Mould can be removed for cleaning or exchange by (see images below) : Removing the gas flush tube Removing the thermocouple and wiring connection Updated: 10 October, 2009 Page 11 REF: REI-90-0611
Removing the black screw Holding the bottom part of the upper mould, slowly pull/ slide out 6.2 Lower Mould Lower Mould Function The main function of the lower mould is to hold the containers on their position for the sealing and the cutting function. Exchanging Simply remove the black screw from the bottom of the lower mould and pull out the lower mould. 9. Maintenance and Cleaning ELECTRICAL HAZARD Always REMOVE the machine from the power outlet before performing any maintenance or cleaning works. BURN HAZARD Cleaning and maintenance should be performed by your trained personnel only Allow unit to cool at least 90 minutes before normal cleaning Updated: 10 October, 2009 Page 12 REF: REI-90-0611
If hot machine must be opened, keep hands away from upper moulds and the printer. USE HOT PAD GLOVE IF IT IS NECESSARY TO HANDLE THE MOULDS WHILE IT IS STILL HOT (although not recommended). 9.1 Daily Maintenance Wipe with wet cloth the upper and lower moulds with dirt. Always remove residual films (plastic roll films). DO NOT SCRAPE THE MOULD WITH SHARP OBJECTS. Use scouring pads like Scotch Brite to clean the plate. Clean the groove of the lower sealing mould Clean the sensor if necessary 9.2 Air Pressure Controller Regularly check the air pressure controller (once every month). Check lubricant oil every month. If less than 50%, refill the lubricant oil (Specification: Number 68) 10. Trouble Shooting Guide A. There are nine error codes provided for easily understanding the machine status. A. EAC: Voltage error. B. E00: Temperature control system error. C. E01: Heating system error.( Heater burnt, thermocouple broken, or PCB broken). D. E02: Upper mould cylinder sensor or limited switch (Top area) error. E. E03: Limited switch error (Lower mould output stop). F. E04: Sealing film is used up, out off position, or eye-mark sensor error. G. E05: Limited switch error (Lower mould input stop). H. E06: Upper mould press down error, or limited switch (Down area) error. I. E07: Safety door is touched or collided. J. E08: Any other limited switch(random) out of position. K. E09: No air pressure or air cylinder sensor error. L. E11: Limited switch out of position (Lower mould input stop) M. E12: Limited switch out of position (Upper mould go up stop) N. E13: Date printer no action over 10 seconds (Model: ET-69M&59L) O. E16: Parameter setting over original design. P. E17: Parameter setting couldn t be read. Q. E18: Parameter setting couldn t be re-typed or keyed in. R. E19: P.C board error. S. E20: DC power circuit short (P.C board error). B. If any error occurs, an alarm will sound. To stop the alarm, please off the power for five seconds, then turn on the power again, if the alarm remains on, please contact your Super Sealer for service. ERROR CODE E00 ERROR MESSAGE POSSIBLE CAUSE SOLUTION Temperature control 1 temperature wire error. 1 Correct the temperature wire. system error. Updated: 10 October, 2009 Page 13 REF: REI-90-0611
system error. 2 P.C.B error 2 Change P.C.B E01 Temperature control system error. Heater not turned on after power is on. Heating circuit error. Heat up time over 7 minutes, cannot reach set temperature. b. Temperature too high (200 ), the heater remains on after set temperature. Power on failed P.C.B error Heater error Heating wire error Reboot the power on key. If fail again then. Change P.C.B Change new heater. Change new heating wire. Power off wait till temperature lower than set value then re, start the power again. If happen again replace the PC Board. E02 Upper cylinder operating system error. No air pressure Cylinder sensor error Open air valve on compressor. Check the cylinder position sensor. E03 Lower mould system error. Error appears right after the power on Check the out position micro switch. Check the micro switch wire. Replace the PC board. E04 E05 Sealing film is used up, or eye-mark sensor error. Lower mould Position switch error Error appears when the lower mould moves out half way Error for un-smooth lower mould movement. Sealing film dressing error. Check the film eyemark sensor Lower mould does not move in position Lower mould moved in but upper mould does not press down Check the jack up system. The bearing roller may go out off the slide way. Clean both the slide ways and bearings of the lower mould system. Or replace the dirty bearing. Correct the film dressing. Clean, adjusting the eye-mark sensor Change new sensor. Check the micro switch wire and micro switch Change the wire or micro switch if failed again. E06 E07 Upper mould press down error. Safe door is touched or collided. No air pressure Safety door error Check the air cylinder and air pressure system. Adjust the switch of Safety door. E19 P.C board error. P.C.BOARD error Change new P.C.BOARD ITEM POSSIBLE CAUSE SOLUTION (1) The cutter cut the edge of container The upper and lower mould misalignment. Check both the front and rear micro switch of the lower mould. Updated: 10 October, 2009 Page 14 REF: REI-90-0611
(2) Sealing film stop at wrong position after sealing. (3) Poor sealing performance Film eye-mark sensor in wrong position Film stop is in wrong position. Film material is not suitable for the container. The heater is not clean. Sealing time is too short. Cutter is not sharp. The groove between the cutter and heater is not clean. Adjust the eye-mark sensor position and clean the sensor. Adjust the film roll and clamp. Change the film material. Clean the heater. Increase the sealing time. Change a new cutter or resharp the cutter. Clean the groove. Updated: 10 October, 2009 Page 15 REF: REI-90-0611
11. Wiring Diagram Updated: 10 October, 2009 Page 16 REF: REI-90-0611
Updated: 10 October, 2009 Page 17 REF: REI-90-0611