Sealer Closer-Instruction Manual

1492LS09.
DOC
OPERATION AND MAINTENANCE
SAPAC SEALER CLOSER MODEL 41B DFA - EL PASO

OPERATION AND MAINTENANCE MANUAL
CONFIDENTIALITY This document contains information, which is valuable and confidential to Colby Powder Systems Pty Ltd (Colby) and Colby Systems Ltd (Sapac) and is intended for disclosure to and use by the intended reader only. It is a condition of supply of this document that the reader may not without the prior written consent of Colby Powder Systems (a) Copy or reproduce any part of this document, or (b) Disclosure any part of this document to another person.
PROJECT NO: SERIAL NO: DOCUMENT REF: CUSTOMER: AUTHOR: EDITION NO: DATE:
1492 LS09 1492LS09

DAIRY FARMERS OF AMERICA
M.W. 1 30-04-01
1492LS09.DOC
Read this manual completely before starting-up or operating this equipment. Be certain all personnel concerned with this machinery are fully alerted to the possible hazards of the equipment and its utilities (electrical & pneumatic) before any operation is allowed.
Colby accepts no liability for any claims with regard to equipment damage, personal injury, death or incurred costs caused by the improper installation, operation or maintenance of the supplied equipment. The information contained in the manual is accurate at the time of writing, however Colby reserves the right to make improvements to their products, to benefit the end-use, without notification. All rights are reserved with respect to Patents, Designs and Copyrights.
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PREFACE
This Operation and Maintenance Manual has been prepared by Colby Systems for Dairy Farmers of America, El Paso. When making inquiries, please quote the Colby project number #1492 and the project designation, - Powder Handling and Packing. The purpose of this Manual is to provide data for the proper operation and maintenance of your SAPAC equipment. The instructions given in this manual are mandatory for the correct operation and maintenance of the SAPAC machines supplied. For warranty claims, please refer to the Colby standard Warranty Terms and Conditions.
Colby Systems Ltd.(Sapac) 30 Sir William Avenue Greenmount Auckland New Zealand Phone: +64-9-274 9554 Fax: +64-9-274-6488 E-mail: spares@colbypowder.com
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TABLE OF CONTENTS
1. 2. 3. Revision Control Sheet .................................................................................... 1-1 Scope and Intended Reader ............................................................................ 2-1 2.1. 3.1. 3.2. 4. 5. Scope ........................................................................................................ 2-1 Abbreviations ......................................................................................... 3-1 Definitions............................................................................................... 3-1 Abbreviations and Definitions ....................................................................... 3-1
References ......................................................................................................... 4-1 Safety.................................................................................................................. 5-1 5.1. 5.2. 5.3. Packaging - Commitment to Safety..................................................... 5-1 General Safety Procedures.................................................................... 5-1 Safety Precautions.................................................................................. 5-2 Introduction ............................................................................................ 6-1 General Arrangement ........................................................................... 6-2 Operating Instructions .......................................................................... 6-3 Introduction ............................................................................................ 7-1 The Switch Buttons and Indicator Lamps .......................................... 7-2 The Temperature Controller ................................................................ 7-5 Leveller .................................................................................................... 8-1 Cleaner Section ....................................................................................... 8-4 Seal Heating ............................................................................................ 9-1 Seal Compression................................................................................... 9-5 Seal Scoring............................................................................................. 9-6 Seal Compression/Scoring Wheel Adjustment................................. 9-7 Seal Cooling ............................................................................................ 9-8
6.
Start up And Operation................................................................................... 6-1 6.1. 6.2. 6.3.
7.
Control System ................................................................................................. 7-1 7.1. 7.2. 7.3.
8.
Leveller And Cleaner...................................................................................... 8-1 8.1. 8.2.
9.
Heat Sealing ...................................................................................................... 9-1 9.1. 9.2. 9.3. 9.4. 9.5.
10. Bag Top Closer Section .................................................................................. 10-1 10.1 Bag Top Closer ..................................................................................... 10-1 10.2. Bag Top Compression ......................................................................... 10-5 11. Conveyor ......................................................................................................... 11-1 11.1. Introduction .......................................................................................... 11-1 11.2. Conveyor Specifications ..................................................................... 11-1 12. Electrical .......................................................................................................... 12-1 13. Pneumatics ...................................................................................................... 13-1
Table of Contents
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13.1. Pneumatic Lubrication (For machines with airline lubrication)............................................................................................ 13-1 13.2. Pneumatic Schematic........................................................................... 13-3 13.3. Pneumatic Components ...................................................................... 13-3 14. Troubleshooting & Maintenance ................................................................. 14-1 14.1. Levelling Mechanism .......................................................................... 14-1 14.2. Levelling Mechanism .......................................................................... 14-3 14.3. Cleaner Mechanism ............................................................................. 14-4 14.4. Heating Dies ......................................................................................... 14-6 14.5. Seal Compression Wheels................................................................... 14-7 14.6. Seal Scoring Wheels ............................................................................. 14-9 14.7. Seal Compression/Scoring Wheels Drive Chain .......................... 14-10 14.8. Bag Top Closer ................................................................................... 14-11 14.9. Air Heating Element.......................................................................... 14-12 14.10. Drive Train.......................................................................................... 14-15 14.11. Carrier Belts ........................................................................................ 14-22 14.12. Conveyor............................................................................................. 14-26 15. Spare Parts ...................................................................................................... 15-1 15.1. Spare Parts Requirements................................................................... 15-1 15.2. Illustrated Spare Parts ......................................................................... 15-2 15.3. Essential Spare Parts.......................................................................... 15-18 15.4. Recommended Spare Parts ............................................................... 15-19 16. Appendix A..................................................................................................... 16-1 16.1. Pneumatic Circuits .............................................................................. 16-1
Authorised by :....................................................
Date : ...........................................
Table of Contents
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1.
REVISION CONTROL SHEET

Revision Edition 1 30/04/01 Mark Winter New document
All sections
1. Revision Control Sheet
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2.
2.1.
SCOPE AND INTENDED READER

Scope
This document is the operating manual for the Sapac Sealer Closer Model 41B machine and its associated controller system. It is directed to the personnel involved in both the day-to day operation of the machine, and the diagnosis and correction of faults. It also provides information on the mechanical maintenance of the machine. Some electronic details are included for convenience. More detail, particularly on the controller is contained in the electrical/electronic operators manual.
2. Scope and Intended Reader
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3.
3.1.
ABBREVIATIONS AND DEFINITIONS

Abbreviations
A-B Ack C/B CC D/A E-Stop I/O N/C N/O P&ID P.B PE PLC PX RF RIO SCADA TOL Allen Bradley Acknowledge Circuit Breaker Control cabinet Double Acting (cylinders) Emergency Stop PLC Inputs and Outputs Normally Closed Normally Open Process and Instrumentation Drawing Push Button Photo Electric Switch Programmable Logic Controller Proximity Switch Radio Frequency Remote Inputs and Outputs Link Supervisory Control Advisory and Data Acquisition Motor Thermal Overload
3.2.
Definitions
Colby Sapac Colby Systems Ltd. Colby Systems Ltd
3. Abbreviations and Definitions
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4.
REFERENCES
.1. This document refers to:Name 25/2 Rotary Packer Bag Loader Neck Stretcher Sealer Closer Model 41B Electrical/Electronic Operator Description Operation and Maintenance Manual Operation and Maintenance Operation and Maintenance Manual Operation and Maintenance Manual Electrical/Electronic Operators Manual Revision 1 1 1 1 1
Document Type Sapac Manual Sapac Manual Sapac Manual Sapac Manual Sapac Manual
4. References
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5.
5.1.
SAFETY
Packaging - Commitment to Safety
Colby is committed to supplying Packaging Systems that provide a safe working environment for your company. However, safety also requires a continuous commitment from you, in the proper use, operation and maintenance of all the equipment supplied. It is important that operating and maintenance personnel be instructed in recognising hazards and relevant safety procedures. Staff should be encouraged to report any accident, no matter how minor, so that its effect on safety can be immediately assessed. The realisation that they could suffer injury is often a powerful incentive to their observance of this, but it would help if you, as the employer, can be seen to take notice of their reports and have serious faults rectified immediately. Colby recommend the Standards contained within this section be implemented and used by you.
5.2.
General Safety Procedures.

As the customer, it is your responsibility to establish a maintenance program, which ensures that all equipment is kept in a safe condition. For each piece of equipment supplied by Colby, details of the maintenance requirements can be found in the relevant section of this manual.
IMPORTANT - Read this NOW
The following conventions are used in Colby manuals:
Warning: This symbol means that people may be injured if the procedures are not followed.
Caution: This symbol means that equipment may be damaged if the procedures are not followed.
.1. .2.
All maintenance must be carried out by trained personnel. Only trained Employees shall be permitted to operate equipment. Training shall include instruction in operation under both normal and emergency conditions.
5. Safety
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.3.
This equipment comprises of Electro-mechanical devices, which are capable of unexpected motion. Where possible steps have been taken to guard this equipment through the use of physical as well as electronic safety features without inhibiting its function. However certain safety practices need to be followed to minimise the inherent dangers associated with any Electro-mechanical device.
5.3.
Safety Precautions
Following is a list of recommendations for your guidance and safety. These must be adhered to at all times. Further, more specific, safety recommendations are listed at other relevant locations throughout this manual. We recommend that you incorporate the following safety precautions and this manual as part of your Companys Safety documentation system.
Read this manual completely before starting-up or operating this equipment. Serious injury and/or equipment damage could result from improper operation of this equipment and not heeding all safety recommendations Only suitably qualified and trained personnel should operate and maintain this equipment Be certain all personnel concerned with this machinery are fully alerted to the possible hazards of the equipment and its utilities (electrical & pneumatic) before any operation is allowed Determine the location of all emergency stop devices and air/power isolators (disconnects). When the air or power supply isolators are switched off a lockable hold card or similar system should be employed so that air or power is not reconnected until the equipment is in a safe and satisfactory state. Disable the machine by isolating (disconnecting) and locking air and power supply to the equipment before attempting any cleaning, maintenance or manual testing of components. Be aware that on machines that have heating devices these may be hot for some time after the power has been removed. Be sure all guards are in place and observe all warning signs. Do not remove or open guards while the machine is running
5. Safety
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There will be occasions when the machine stops because of a fault condition. When the fault clears the machine may start again without warning. Remain well clear of the machine at all times while in operation. Never start equipment without first checking that loose objects, tools and all personnel are clear of the machinery. All personnel in the immediate area of the equipment should be alerted prior to stating. Observe extreme caution when switches are turned on and the equipment is operational. Do not attempt to beat the machine by reaching into areas where there are moving or hot parts. Ensure that the machine and all electrical equipment is free of any accumulation of water, dust or other contamination. Do not open junction boxes or control panels unless you are a qualified electrician. Be sure power is isolated. Except when electricians are performing maintenance, electrical enclosures and junction boxes should always be securely closed. The EMERGENCY STOP is a large red illuminated pushbutton-labelled EMERGENCY STOP. Some equipment is also fitted with a red emergency stop pull-wire. Both types of emergency stop devices are latching so once the emergency stop device has been activated it will remain in that state until it is reset (or unlatched) When pressed the Emergency Stop button/wire will disconnect all output control voltage. Be aware that on machines with heated surfaces these may remain hot for sometime after the Emergency Stop has been activated. Never rely on the Emergency Stop to isolate a machine. Isolation of equipment must be performed using the main air and power isolators (disconnects) Never reset the Emergency Stop if someone else has left it on. Before unlatching the Emergency Stop and restating the machine ensure that all personnel, tools and other equipment are clear of the machine and that it is in a satisfactory state to begin operation
5. Safety
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6.
6.1.
START UP AND OPERATION

Introduction
The Sapac Sealer Closer basically comprises of four sections. These sections are covered in detail in this manual (sections 8 to 10). Further details on electrical pneumatics and spares are covered in their own separate sections.
6.1.1
The purpose of the Sapac Sealer Closer is to: Accept a bag which has been neck stretched and deaerated (usually by the Sapac Bag Presenter), into the levelling section. Level the bag top to allow re-activation further on in the machine. Clean the seal area of any contamination, which may affect seal integrity. Heat-seal the inner liner through the outer paper plys. Score the inner liner to release it from the paper outer. Compress the still plastic liner seal to ensure a hermetic seal. Cool the sealed liner (and paper) to provide a strong seal before any load is applied to it in subsequent handling after the machine. Reactivate the pre-applied hot melt adhesive and close the top stepped end of the bag. Compress the reactivated top of the bag to ensure secure adhesion to the paper.
The entire Sealer is controlled by a PLC, which provides outputs to the solenoid valves, which perform the sequencing functions. Most of these are pneumatic valves acting directly from the output. There is no pneumatic logic as such involved. The PLC also receives inputs from the various sensors on the machine which act to identify the status of the bags being processed and the overall machine status.
6. Start up And Operation
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6.2.
General Arrangement
Figure 6.2 Right to Left Feeding Machine
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6.3.
Operating Instructions 6.3.1. Start Up

Ensure that the mains isolator (disconnect) at main control cabinet is switched to the ON position and that the Emergency Stop illuminated push button on the operators control panel is unlatched. Select the Sealer Heat and Closer Heat illuminated selector switches to ON. Depending on whether or not the product being packed requires the liner seal area cleaned select the required function at the Bag Seal Cleaner switch (OFF/ON). Assuming that the packed bags are required to be closed as well as sealed, select this function also by turning the Bag Top Closer Flap illuminated selector switch to DOWN.
Note:
While the heating zones are below their operating temperature envelope (10 units either side of set point) the Sealer Heat Alarms (red indicator lamps under each zone controller) will remain illuminated.
The sealer up to heat condition is indicated when the Zone Alarm Lamps are extinguished and the Drive/Conveyor Start/Stop illuminated push button switch may now be operated to make the machine operational.
Note:
We recommend that whenever the Sealer Heat Switch is selected to ON (after having been switched off) that a Seal/Closure test be carried out on an empty bag prior to full line start-up.
While performing the above seal test, a good opportunity exists to check that the Sealer Carrier Belt speed is synchronised with the conveyor speed below i.e. as the test bag leaves the leveller section, keep a visual check on the bag bottom speed compared to the conveyor speed. Should the carrier belt speed appear to need adjustment, refer to Operator Adjustments below.
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6.3.2. Operator Adjustments

Operator Adjustment of the carrier belt speed may be necessary should there be a change to line speed. The Sealer/Closer Frequency Drive Speed control adjuster is a calibrated dial with level lock to prevent accidental adjustment. The adjuster is located in the top left-hand corner of the Low Voltage electrical cabinet beside the Motor Overload reset switch. To synchronise the carrier belt speed with that of the bag conveyor first feed an empty bag into the leveller section being careful to ensure that it is within the admissible levelling height. As the bag exists the leveller section, mark the conveyor belt at the bottom leading edge of the bag so that the relative distance between bag edge and mark can be monitored. If a gap opens up between the mark and the bag edge (mark edging), then the carrier belts are moving slower than the conveyor belt. If the bag edge overtakes the mark then the reverse is true. To speed up the carrier belts, release dial lock of the speed adjuster and turn dial clockwise until desired increase in speed is achieved. To slow down the carrier belts, release the dial lock and turn dial anticlockwise.
Note:
Precise synchronisation can not be achieved in one adjustment, however as long as relative speeds are close enough, fine tuning can be achieved during normal running.
6.3.3. Bag Presentation

All bags must enter the machine at the correct height for the levelling system to operate correctly. A legend plate is located on the outside of the first bulkhead. This shows the minimum and maximum height that the extreme top edge of the bag must fall within so that efficient processing through the machine is ensured. See Figure 6.3.3 below.
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MAX. BAG HEIGHT MIN.

Figure 6.3.3 Bag Height Label
Note:
1.
It is important that the right size bags are in use for the product being packed ie. If the bag is too small, then there will not be enough head space (above the product) for the bag to be transported through the machine which will result in regular jam-ups and/or bag damage. Similarly if the bags are too big, then this could cause the bag to entrap unwanted air above the product resulting in unstable pallet stacks.
2.
The nominal headspace requirement prior to neck stretching between product and bag top is 250mm (10 inch).
6.3.4. Machine Height

To make a downward height adjustment of the machine, place a typically filled bag on the conveyor prior to the Neck Stretcher (Bag Presenter) and start the line. When the bag enters the leveller section it will be stopped by the awaiting Bag Stop Arm. The operator should immediately stop the Sealer Drive/Conveyor via the control panel. If electric height adjustment has been provided as an option, it will be necessary to use the UP/DOWN momentary contact selector switch on the operators control panel, otherwise the height adjustment is made via the handwheel provided on top of the machine pedestal. The operator can now adjust the machine height downwards lightly compressing the head space in the bag so that the leveller section undercarriage is lighting pressing down on the product and its bag.
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Note:
Final operating height is obviously dictated by the ease of passage of filled bags through the machine.
The Sealer can now be started up again and the test bag can be driven through the machine in the normal manner.
Prior to switching on the packing machine and going to full line automation the following requirements should be checked according to preceding information.
Note:
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6.3.5. Line Start-Up Check List
Is the bag the right size for the product being packed? Yes Is the Sealer set to the right operating height? Yes Are the carrier belts synchronised with the bag conveyors? Yes Are the heating zones up to temperature? Yes Has a satisfactory seal test been done since the machine was last shut down? Yes Is the downline equipment all active so that line control interlocks are operational?
No
Source right size bag. See Section 6.3.3.
No
Make adjustments. See Section 6.3.4.
No
Synchronise Carrier Speed. See Section 6.3.2.
Belt
No
Wait for alarm lamps to extinguish.
No
Do Seal/Closure Test. See Section 6.3.1.
No
Remedy prior to starting up Packing Machine.
You are not free to carry out the Packing Machine Checks prior to running the line in automatic mode.
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Line Start-Up Check List cont Provided that the Sealer/Line preparation has been carried out as per preceding pages, when filled, the Neck Stretched deaerated bags will enter the Sealer Carrier Belt nip pulleys and be gripped by the carrier belts and fed up to the Bag Stop Arm. The Levelling Clamp Rollers will quickly separate the drive belts and immediately drive down the bag top until the leveller photo-eyes are uncovered. The Bag Stop Arm will now withdraw allowing the Bag to proceed through the machine and on down the line.
Note:
The following Sections 8, 9, & 10 outline the mechanical adjustments that may be necessary from time to time for fine tuning the machines performance.
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7.
7.1.
CONTROL SYSTEM
Introduction
The Sealer/Closer control system is arranged in three sections - the HIGH Voltage control section, the LOW Voltage control section and the Operators Control Panel/ Cabinet. The HIGH Voltage section of the Control System is located in a lockable electrical cabinet which is fitted with a mains ISOLATOR/DISCONNECT, for isolation of all power to the machine. The thermal overloads, fuses and power contactors that control the motors in the field are also located in this cabinet. The frequency drive that controls the Sealer Drive and the switching contactors for the Sealer/Conveyor motors are located in the high Voltage cabinet. All precautions stated by the frequency drive manufacturer must be observed when working on any Variable Frequency drive. In the LOW Voltage section of the Control System is the Allen Bradley 500 programmable Logic Controller. All LOW Voltage Control is accomplished using 24 Volts AC. All control switches and outputs are on 24 Volts AC supply while inputs, some lamps and temperature controller outputs, are on 24 Volts or less DC supply. The function of the PLC is to monitor various control switches and field sensors and with the use of the Ladder Logic, sequence the machine in a logical and safe manner. Since any automated machinery is totally reliant on the feedback from the various switches and sensors, it is important that these are not tampered with in any way and that they are checked and maintained on a regular basis. The switches and sensors may only be adjusted by a qualified Technical Engineer. There are basically four main sections of control: the Leveller, Cleaner, Heating and Closing sections. Refer CAL 3200 Temperature Controller Operation, in the Appendix, for setup procedure on the Heating Sections.
After Power Off, it is possible for the Variable Frequency Drive to have dangerous residual voltages present for up to 30 minutes. Extreme care must be exercised when working with Variable Frequency Drives. For total isolation of mains supply to the system, the lockable Mains Isolator located on the Electrical Cabinet must be turned off and locked for total safety.
Warning:
7. Control System
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7.2.
The Switch Buttons and Indicator Lamps

All Control Buttons and indicators are located on the control panel of the control cabinet on top of the Sealer Spine. Please refer to the Control Panel layout drawing Figure 7.1.11 for reference. 7.2.1. Drive/Conv. Stop/Start Flush P.B. Switch (Green) The Start/Stop switch is a momentary contact illuminated push button switch which switches via the P.L.C. Ladder Logic from stop to start to stop on alternative operation. When switching from STOP to START it enables the Sealer Drive/Sealer Conveyor to start-up and run (interlocks permitting) via main contactor No.6 in the High Voltage Section of the Main Control Cabinet.
7.2.2.
Emergency Stop Latching Mushroom Button Switch (Red) The Emergency Stop switch is an illuminated large mushroom button labelled EMERGENCY STOP and is provided to allow the machine to be stopped immediately in the event that injury to personnel or damage to componentry is imminent. When this button is pressed, all machine control voltage is aborted without delay, thus power is removed from all control P.L.C. outputs. The EMERGENCY STOP button is self latching when pressed and must be pulled out to release. Extreme care must be exercised to ensure that all personnel are clear of the machine before releasing the EMERGENCY STOP button. A red indicator integrated in the button is illuminated whenever the EMERGENCY STOP is activated. NEVER release the EMERGENCY STOP if someone else has left it latched on. Once you have activated the EMERGENCY STOP button, ALWAYS check with all other personnel working on the machine before releasing it, and then make them aware that the machine has been returned to its normal operating conditions, ready for start-up.
7.2.3.
Sealer Heat OFF/ON Selector Switch (Black) The Sealer Heater Selector Switch is a plain maintained two position switch which, when switched to ON, allows the Temperature Controllers to bring the heating zones up to set-point temperature via main contactor No.4 in the High Voltage section of the main control cabinet.
7.2.4.
Closer Heat OFF/ON Selector Switch (Black) The Closer Heat Selector switch is also a plain maintained two position switch which, when selected to ON, interacts with the Closer Air Pressure switch (via P.L.C. output) to allow the Closer heating zone to come up to set point temperature by switching Main
7. Control System
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Contactor No.3 in the High Voltage section of the main control cabinet.
7. Control System
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7.2.5.
Seal Heat and Closer Alarm Indicator Lamps (Red) The Heat Alarm indicator lamps are powered by incandescent bulbs via the Temperature Controller alarm outputs which are programmed to give both over and under temperature conditions.
7.2.6.
Bag Sealer Cleaner OFF/ON Selector Switch (Orange) The Bag Seal Cleaner switch is a two position illuminated selector which when switched to the OFF position negates the Bag Liner seal area cleaning operating via the P.L.C. Ladder Logic programme. When turned to the OFF position the selector switch illuminates its indicating lamp so as to draw the operators attention to the fact that the Sealers normal operating attitude has been comprised.
7.2.7.
Cleaner Error/Batch Complete Indicator Lamp (Orange) The Cleaner Error indicator lamp doubles as the Batch Complete indicator i.e. when indicating a Cleaner Error the incandescent bulb flashes from OFF to ON and is simultaneously accompanied by an audio alarm. When indicating the Batch Complete Condition the incandescent bulb is illuminated steady accompanied by a continuous audio alarm for a 5 second period.
7.2.8.
Sealer Height Up/Down Selector Switch (Black) When fitted, the Height Up/Down switch is a mid-position off, three position switch with one momentary contact each for the up and down travel of the Sealer Spine. When operated in either position main Contactor No.s 8 or 9 are energised to operate the geared motor attached to the top of the machine pedestal.
7.2.9.
Bag Top Closer Flap Up/Down Selector Switch (Orange) The Bag Top Closer Flap switch is a two position illuminated selector which when selected to UP, lifts the flap via solenoid valve and pneumatic cylinder. Its purpose is to prevent the re-activation of the pre-applied glue at the bag top OR to avoid folding over the top of the bag when one bag is being put through the machine repetitively after each subsequent seal has been cut-off the bag top for inspection. When the switch is turned OFF, its indicator lamp illuminates continuously. The purpose of this is to indicate that the normal operating attitude of the machine has been compromised.
7. Control System
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7.2.10. Downline Fault Indicator Lamp (Red)

The Downline Fault Indicator Lamp is powered by an incandescent bulb which is illuminated steady when a downline interlock goes false normally resulting in the prevention of further filled bags being processed by the Sealer.
7.2.11. Control Panel
Figure 7.1.11 Control Panel
7.3.
The Temperature Controller

There are three (3) CAL 3200 Temperature controllers in the 41A Sealer Control Panel, each controlling one (1) Temperature Zone see figure 7.2 below. In the Heat Sealing Section (Section 9 of this manual) there are three (3) zones each comprised of one (1) pair of Heating Dies, these are Zones 1 to 3. In the Bag Top Closer Section (Section 10 this manual) there is one (1) Zone which controls the Air Heater Element Zone 5.
7. Control System
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Figure 7.2
Operator Adjustment

Note:
View setpoint Increase setpoint Decrease setpoint
To reset alarm or fault message Momentarily press together
Ex Factory Setpoint for Zones 1-3 is 2200C (4300F) and Zone 5 is 2300C (4450F)
7. Control System
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8.
8.1.
LEVELLER AND CLEANER

Leveller 8.1.1. Bag Stop Arm Operation
The Bag Stop Arm is used to skid the base of the bag on the conveyor belt while levelling takes place. The most critical setting on the Stop Arm is its height. This is usually about 250mm (10 inch) to 300mm (12 inch) to the paddle centre from the top of the conveyor belt. Essentially, the arm should always be against the vertical part of the bag, as this is consistent in position. If the arm is against the flared out toe of the flat tube bag, the position of the bag bottom will vary. This will cause the bag top to keep moving after the bottom has stopped and tend to tip the bag forwards. The sketch below shows the correct position of the stop arm.
Figure 8.1.1
8. Leveller And Cleaner
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8.1.2
Clamp Cylinders and Levelling Roller Operation Assuming Bag Presentation (Section 6.3.3) requirements, in Startup and Operation Section have been met. The incoming bag operates the No.2 photo-eye which initiates the Levelling Sequence as follows: Leveller rollers clamp onto the bag separating the Infeed carrier belts. Leveller motors wind down the bag top until photo-eye beams transmit across the top of the bag. Bag stop arm retracts and the Leveller Rollers simultaneously unclamp enabling the Infeed carrier belts to grip the bag. Together with the Sealer Conveyor, the Infeed carrier belts transport the bag into the Cleaning Section carrier belt nip.
Figure 8.1.2
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Note:
The clamp cylinders should operate at full speed thus ensuring repeatability. Failure to do so can result in the in-coming bags to topple in one direction or the other. See TROUBLE SHOOTING Section 14 for fault finding.
8.1.3
Levelling/Bar Too Low Photo Cell Care For correct functioning of the leveller, ensure that the photo cells are kept clean. Powder build-up on their faces will reduce efficiency.
Note:
Air jets are mounted below each photocell which blow clean dry air across their faces to reduce powder build up. These jets should always be directed at the red light emitting from the photocell.
To clean the photocell properly, it is necessary to remove the 2 x M6 cap screws and lift the plate and photocell assembly clear of the dust extraction chamber. It is advisable to mark the position (centreline of the photocell) on the front of the guide to which it is bolted. Once cleaned, it can then be reinstalled at the same height.
Note:
Care should be taken to ensure that the reinstalled photocell has a clear line of vision through the hole in the front guide bar. If it is misaligned or over sensitive it may occasionally pick up the edge of this hole, and cause erratic operation.
Partial cleaning of the photocell can sometimes be achieved without removing it. This can be done with a warm damp cloth through the holes in the guide bars. This is only an interim solution, and thorough cleaning should take place once production pressures permit.
8.1.4
Bag Too Low/Bag Length Photo Cell This photo cell, closest to the infeed, is positioned slightly lower than the low bag accept label and the levelling photo cells. It serves two purposes: 1. To reject bags that have entered to low. 2. To auto track the bag width in conjunction with the encoder. This allows the sealer to monitor width changes.
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This enables us to auto tune/adjust the following: Bag central in leveller. Cleaner entry and exit from bag time. Reactivating flap auto raise and lower time. Bag central at tuner.
8.2.
Cleaner Section
8.2.1 Cleaner Operation The purpose of the cleaner is to clean the seal area prior to heat sealing. Good quality seals can only be obtained if there is no contamination in the seal area. refer to Diagram 8.2.1. Clean unlubricated air is used for this purpose. This air supply is filtered by the pure-air filter (Norgren 64 Series also used in the air heater on the Reactivation Station). Further details on the Air Service Equipment are in the Pneumatics Section 13. The cleaner section also incorporates a dust collection duct which when connected to the dust extraction mains, draws away any air borne dust blown from the seal area. The dust extraction is controlled by a pneumatically actuated butterfly valve which is only open when there is a bag in the cleaner section. When a bag enters the cleaner section, the cleaning cycle is initiated as follows: The bag opener cylinder retracts and pivots the vacuum cup onto the face of the bag. Vacuum is applied to this cup via a pilot operated pneumatic valve. Once the vacuum cup has adhered to the bag, the bag opener cylinder extends to pull away the front half of the bag from the rear half, thus forming an envelope for the cleaner probe to swing into. The cleaner probe swings down into the bag. The cleaner probe Air Jets blast away powder contamination from the liner seal area. The cleaner probe swings up just in time to clear the trailing edge of the bag.
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Figure 8.2.1
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9.
9.1.
HEAT SEALING
Seal Heating 9.1.1. The Heating Zones
Heat sealing takes place immediately after seal cleaning. There are three individually controlled heating zones on the Model 41A machines. These are Zones 1-3, each zone comprising of 2 front and 2 rear heating dies. Typical zone heat up time form ambient (12-18 degrees Celsius) to a setpoint of 225 degrees Celsius is 8-10 minutes.
9.1.2.
The Temperature Controllers

Temperature control is carried out by four (3) solid state temperature controllers housed in the control panel. These constantly monitor the temperatures of each zone, showing the individual zone temperatures. The temperature for heat sealing is set during commissioning. It should not be necessary to alter this unless conditions such as machine speed or bag construction change. When the machine is up to operational temperature, the temperatures of the zones will stabilise. This can be seen from the digital displays on the temperature controllers. These are small L.E.D.s located above the top L.H. corner of the digital displays. These L.E.D.s will flicker ON continuously during zone heat-up and then go to OFF when that zone reaches its setpoint temperature. They will then flick from OFF to ON and to OFF as they pulse control power out to the Line Voltage control cards housed in the Field Control Boxes to maintain setpoint temperature. Full details on the temperature controller are contained later in this manual. See the Appendix B. Indicator lamps are on the control panel for each zone. These lamps illuminate during overheat or underheat conditions.
Note:
As there is only one temperature probe (thermocouple) into one of the four dies per zone, failure of 1 or more of the remaining 3 dies to heat up will not be shown on the temperature controller readout.
9. Heat Sealing
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9.1.3. The Field Control Boxes

Each zone has its own Field control on the back of the machine spine. This houses wiring terminations, fuses and solid state relays for switching Line Voltage on and off. Most importantly, there are fuse failure L.E.D. labels on the face of each box. These should be checked whenever a suspect seal check is recorded and at each start-up. An ON L.E.D. indicates fuse failure for that particular heating die. In this case an electrician should be called to investigate the cause of the fuse failure.
Figure 9.1.3 Fuse Failure L.E.D Label
9. Heat Sealing
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9.1.4. Heating Die Adjustments

Heating die adjustment is only required if there is a change in bag construction or there are doubts about seal quality. The rear dies are fixed, so only the front spring loaded dies are adjustable. The dies are factory set and again checked during commissioning. For a standard 4 ply tubular multiwall bag, of 1.2mm (0.048 inch) thickness, the gap between the dies is 0.5mm (0.020 inch), giving a preload of (0.028 inch) 0.70mm. To adjust the die gap, read the following in conjunction with Figure 9.1.4 later in this section ( Letterers in brackets refer to this diagram). 1. Back off M5 tension screws (B) using an 8mm open ended spanner. To do this loosen the lock nut and back the screw off until it is flush with the inside of the stainless plate which it is screwed through. Loosen the main M6 mounting bolts (A) and slide the slotted mounting block forward until the front die is just touching the fixed rear die. As this block is tapered, it may be necessary to loosen the M6 bolts quite a long way before the block can slide fully forward. Retighten the M6 (A) bolts when the block is fully forward, and just touching the fixed rear die. Using the 8mm open ended spanner to adjust the M5 (B) screws, and a feeler gauge or similar to measure the gap, wind in the M5 (B) screws until the gap opens up to an even amount at each end. The feeler gauge or gap setting should be 0.7 or 0.5mm (0.028 to 0.030 inch) thinner than the thickest part of the in bag in use. It is usually necessary to first measure the bag thickness using verniers or a micrometer and then determine the gap accordingly.
2.
3. 4.
5.
9. Heat Sealing
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Figure 9.1.4 Die Gap Adjustment
9. Heat Sealing
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9.2.
Seal Compression 9.2.1. Description

The purpose of seal compression is to consolidate the plastic seal surfaces together to form an effective airtight and ascetically acceptable seal. This is accomplished immediately after the Heat Sealing Section, approximately central on the Sealer. The Carrier belt terminates at this point as the drive is transferred from the Drive Carrier belt via a Simplex Chain Drive.
Note:
Too much pressure from the compression wheels will thin the molten plastic in the seal section and leave a weakened and ineffective seal. Too little pressure will result in an ascetically unacceptable or barely adequate seal.
The correct compression pressure will result in a seal that will have an even opaque appearance. Too much compression pressure can be observed as holes through the seal wherever the highest pressure points are, e.g. coinciding with Kraft seams. Too little pressure can be observed as a mottled pattern of clear and opaque patches along the seal section.
Note:
Although seal compression is an integral aspect of seal quality, it must not be forgotten that the biggest contributor to seal qualify is sealing temperature which can be effected by machine speed and cleaner efficiency.
9.2.2. Operator Adjustment

Although both the rear and front Seal Compression wheels are adjustable, adjustment of the rear Seal Compression wheel should not be necessary as it is preset during assembly, so as the outside diameter is along the centre line of the bag path. Access to the adjustments on the rear Seal Compression wheel is restricted, and any attempt at adjustment should be avoided, unless a major change in bag construction dictates this action. Seal Compression adjustment is via the FRONT Seal Compression wheel. Adjusting bolts are readily accessible. See Section 9.4 (Letters in brackets relate to letters in Figure 9.4).
9. Heat Sealing
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9.3.
Seal Scoring 9.3.1. Description

The purpose of the scoring wheel is to score (Cut by compression) through the sealed part of the inner plastic liner, along its top edge and up to 1mm (0.040 inch) down from this edge, while the seal is in a soft, pliable state. Separation of the filled liner from the portion trapped by the reactivated bag closure effectively frees the pouch within its multiwall outer. The bags outer Kraft is structurally unaltered and remains intact. The Scoring Wheels simply apply pressure to the pliable plastic which causes point of contact thinning leaving a very tenuous connection, if not total separation of the pouch. Although both the rear and front Scoring Wheels are adjustable, adjustment of the rear Scoring Wheel should not be necessary as it is preset during assembly so as the outside diameter is along the centre line of the bag (carrier belts). Access to the adjustment on the rear scoring wheel is restricted and any attempt at adjustment should not be avoided, unless a major change in bag construction dictates this action. Scoring pressure adjustment is via the front scoring wheel.

Scoring Wheel adjustment is carried out in exactly the same way as the Compression roller adjustment i.e. via the FRONT of the machine. See Section 9.4 (Letters in brackets relate to letters in Figure 9.4).
Note:
Scoring wheel gap is critical for good seal quality and long life of components. For standard 4 ply tubular bag, the recommended gap is 0.020 inch to 0.024 inch (0.5mm to 0.6mm). This can vary with bags of differing construction whether this be the number of plys or P.E. liner type.
9. Heat Sealing
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9.4.
Seal Compression/Scoring Wheel Adjustment -Use a FEELER GAUGE or SHIM to set the gap.
Figure 9.2.2 Seal Compression/Scoring Wheels
To Adjust:
1. Loosen the 4 x M8 cap screws which clamp the assembly (1). It may be necessary to also loosen the two adjacent M8 cap screws (1) which clamp the Scoring Wheel. Both PUSH (close gap) (3) adjusters AND PULL (open gap) (2) adjusters are provided. The push adjusters are 2 x M6 grub screws (3) and pull adjuster is a single M6 cap screw (2). Feeler gaugers or shims should be used to set the gap.
9. Heat Sealing
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2. To CLOSE the gap, loosen the M6 cap screw (2) and push the scoring wheel inwards using the 2 x M6 grub screws (3), winding both screws an even amount. Once the gap is correct, nip up the M6 cap screws to pull the assembly tight (2). 3. To OPEN the gap, loosen the 2 x M6 grub screws (3) and pull back the assembly by screwing in the M6 cap screw (2). Once the gap is correct, nip up the 2 x M6 grub screws to hold assembly tight (3). 4. Once the adjustment is correct, tighten the 4 x M8 clamping cap screws (1).
Compression wheel gap is critical for good seal quality and long life off components. For standard 4 ply tubular bag, the recommended gap is 0.030 to 0.040 (0.75mm to 1.0mm). This will vary with bag type, manufacture and construction.
Note:
9.5.
Seal Cooling 9.5.1. Description

The purpose of the cooling section is to start to cool down the seal area of the bag so that downline handling does not rupture a still plastic seal i.e. the cooling process is the seal curing process. The cooling section of the 41A Sealer Closer comprises of one pair of dies. They are located immediately after the scoring/seal compression rollers. These dies have the same profile as the heating dies and are also mounted in the same way.

As the mounting is identical to that of the heating dies, the method of adjustment is the same, refer Section 9.1.4.
9. Heat Sealing
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10. BAG TOP CLOSER SECTION

10.1 Bag Top Closer 10.1.1. Bag Top Closer Assembly
The Bag Top Closer Assembly closes the stepped outer flap and reactivates the hot melt glue to close the outer multiwall bag. This is the CLOSURE. It is comprises of 5 main components as follows: Refer Figure 10.1 1. The BAG TOP CLOSER FLAP which takes the top 41-43mm (and for some bags up to 50mm) (1 5/8 1 inch) of the bag and folds it through 180 degrees to adhere it back against the vertical face of the bag. This guide folds the bag top in two stages, the first being the primary fold and the second being the final fold to adhere it to the bag face. 2. The FRONT FOLD GUIDE over which the top portion of the bag is folded. This supports the front of the bag during folding. 3. The REAR FOLD GUIDE supports the back of the bag during folding. 4. AIR HEATER PLENUM CHAMBER, which contains numerous small holes, on its upper surface, through which the hot air passes, to reactivate (melt) the pre-applied adhesive.
5. The AIR HEATER. Clean dry air passes over the encapsulated
heating element to be heated before entering the air heater plenum chamber.
10.1.2.
Operator Adjustments
Should the factory fold guide adjustment be disturbed, due to disassembly for cleaning or similar, it is necessary to reset them as follows: refer Figure 10.1. 1. The Bag Top Closer flap is first raised via the Operators Control Panel.
2. Part the final drive carrier belts with an engineers steel rule (or
similar) and position alternative at the infeed and exit (parallel) ends of the Rear Fold Guide (R.F.G.).
Note:
Care must be taken when parting the carrier belts as no responsibility is assumed by Sapac Developments for carrier belt damage.
10. Bag Top Closer Section
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If the R.F.G. does not line up with and touch, the inserted rule at both infeed and exit ends; (i.e. the R.F.G. is not parallel to and above the centre line of the bag path) then adjustment may be necessary.
3. To adjust the R.F.G., loosen the Four (4) M6 hold-down bolts at

the rear of the guide and tap forward to comply with 2 above. When alignment is satisfactory tighten down the M6 bolts. position as described in 2 above).
4. The front fold guide (F.F.G.) is set off the R.F.G. (when in correct
To set the F.F.G. loosen the four (4) M6 hold down bolts along the front of the F.F.G. CAUTION: If the Bag top Closer assembly is hot, particular care is advised when loosening the two (2) M6 bolts located under the Air Heater / Plenum Chamber. Gap set the F.F.G. 3mm (1/8 inch) away from the R.F.G. for a standard 3 or 4 ply bag of flat tube construction. Re-tighten the four (4) M6 bolts when adjustment is satisfactory.
Note:
Should bag construction be other than that above, the rule of thumb for gap setting is as follows: Bag thickness measured at thickest point by micrometer or vernier x 2 1/4 = gap setting (initial).
5. With the Closer Flap still raised, manually feed an empty bag into
the machine and observe its passage through the fold guides. When the gap set is satisfactory the Bag Top Closer adjustment can be carried out as follows: with the B.T.C.F. still in the up position manually feed into the machine an empty bag and stop the said bag when it is positioned about centrally in the closer assembly. To stop the machine, operate the Drive/Conv START/STOP button on the operators control panel.
Should the test bag (5 above) hesitate or snag at any point during its passage, through the fold guides the gap set at the point of snagging should be increased to avoid same.
Note:
6. By hand, fold the bag top over the F.F.G. so it is lying horizontally above the plenum chamber. 7. Via the Bag Top Closer Flap UP/DOWN switch (operators control panel) lower the B.T.C.F. and check that it does not pinch the bag top fold directly on top of the F.F.G.
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8. If adjustment of the B.T.C.F. down position is required this must be carried out at the piston rod end of the flap actuator.
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Note:
While there must obviously be enough clearance between the B.T.C.F. and the top of the F.F.G. it is desirable that this clearance be the minimum amount required to allow free passage of the bag since this adjustment is arguably the most critical for producing a parallel fold.
9. The final closure fold is also a function of the B.T.C.F. adjustment. This final fold adjustment is carried out at the B.T.C.F. hinge on the outfeed end of the said flap. So that the final fold follows the original first fold crease, the gap between the diagonally positioned B.T.C.F. rod (see Figure 10.1) and the F.F.G. must be set to about 1 the micrometer or vernier measured bag thickness. 10. To carry out the adjustment as in 9 above, with the B.T.C.F. down loosen the M6 bolt which attaches the B.T.C.F. to its hinge bar and move the flap in or out depending on whether a smaller or greater gap is required.
Figure 10.1 -Bag Top Closer Assembly
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10.1.3.
Air Pressure Requirements

For normal operation initial air pressure setting can be 20 psi. Some variation may be warranted for unusual conditions but generally this can be considered a fixed condition of operation. Dusty products that tend to coat the adhesive applied to the bag might require the air pressure to be increased by 1 or 2 psi. Product contamination of the adhesive area should be avoided where possible. A pressure regulator and gauge are each panel mounted in the front face of the machine spine above the re-activation station. The closer air pressure sensing switch is accessible by removal of the rear inspection panel immediately behind the pressure regulator and gauge.
Note:
The pressure switch is set to raise the CLOSER AIR alarm if the pressure is below 15 psi (trip pressure). The air heater will not switch on below this trip pressure. This reduces the possibility of element burn out due to insufficient air flow.
The pressure regulator is a low pressure type, and has a maximum pressure output of 25 to 30 psi. This maximum pressure can therefore not be exceeded. Layout details of the pneumatics concerned with this station are contained later in this section.
10.2. Bag Top Compression 10.2.1. Description

The purpose of bag top compression is to secure the adhesive bond between the folded over stepped end of the bag and its out ply. After exiting the Bag Top Closer, the folded bag top is gripped between the two compression belts and pressed between them just prior to exiting the machine. Refer to Figure 10.2 for diagram. The compression belts are toothed timing belts which are nonmarking. They are driven directly by the geared drive via timing pulleys.

As the compression belts are inherently low stretch design, the distance between the driving and idling timing pulleys does not need to have adjustment for tensioning.
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The front compression Idle Rollers are sprung loaded against the compression belt and no adjustment has been found to be necessary.
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10.2.3. Compression Belt Cleaning

While the belts themselves could be expected to stay clean when all conditions are perfect; when temperatures are too high, air flow is too great or there is a variation to reactivation adhesive during bag manufacture, some build up may be experienced on the Compression Belts. Adjustable scrapers are fitted to the centre outer side of the belt (one each side) to keep this build up to a minimum. These are set just clear of the belts to remove excess adhesive build up, but can be adjusted closer if, during production, it is felt necessary. ADJUSTMENT is done by loosening the M8 cap screw and pivoting the edge of the scraper in towards the belt face. Always retighten this cap screw after adjustment. CAUTION: DO NOT ADJUST THE SCRAPER TOO CLOSE TO THE BELT OR DAMAGE MAY RESULT, REDUCING BELT LIFE OR DAMAGING THE DRIVE.
Figure 10.2 - Bag Top Compression Assembly
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11. CONVEYOR
11.1. Introduction
The Sealer Conveyor is a standard Sapac build unit and its primary function is to accept bags from the Packing Machine and feed them through the Neck Stretcher and Sealer Closer. The Conveyor speed is fixed and thus the Sealer speed requires synchronising with same. See Section 6.3.2 for a description of this process. The Conveyor head, tail and tension rollers are of an open cage design, running in flange bearings. The belt is standard width and is driven as per specifications below. For belt tensioning and tracking instruction refer to the maintenance section (Section 14.13) .
11.2. Conveyor Specifications
Serial #` Side Length (mm) Belt Length -N.F.L. (mm) Belt Width (mm) Belt Type Belt Construction Drive Theoretical Belt Speed (m/min)
C164 5000 Overall 10800 (425) 300 (12 inch) LEDER 2/U2/UO/6 Endless Spliced to N.F.L. SEW SA57TDT80N4 Geared Electronic Motor 0.75kW/19.2 rpm 6.3
11. Conveyor
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Figure 11 Conveyor
11. Conveyor
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12. ELECTRICAL
Temperature Control Settings 0C Level
1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3 SP1.D SP2.D BURN REV.D REU.L SPAN 2 ERO CHEK REA DATA VER RST SSD RLY 1D2U 1R2R 1N2N 0 0 OFF VAR0 CTA 2 NONE SSD RLY 1D2U 1R2R 1N2N 0 0 OFF VAR0 CTA 2 NONE TUNE BAND INT.T DER.T DAC CYC.Tt OFST SP.LY SET.2 BND.2 CYC.2 SPL.P HAND PL.1 PL.2 SP2.A SP2.B DI.SP HI.SC LO.SC INPT UNIT
Parameter
Zone 1 4 Setting
OFF 21 2.5 11 1.5 10 0 OFF 10 2 ON/OFF 100 OFF 100 100 BAND NLIN 10 300 0 TCJ
0C
Zone 5 Setting
OFF 14 2.7 13 1.5 11 0 OFF 10 2 ON/OFF 100 OFF 100 100 BAND NLIN 10 300 0 TCJ
0C
12. Electrical
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Temperature Control Settings 0F Level

1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3 TUNE BAND INT.T DER.T DAC CYC.Tt OFST SP.LY SET.2 BND.2 CYC.2 SPL.P HAND PL.1 PL.2 SP2.A SP2.B DI.SP HI.SC LO.SC INPT UNIT SP1.D SP2.D BURN REV.D REU.L SPAN 2 ERO CHEK READ DATA VER RSET
Parameter
Zone 1 4 Setting
OFF 21 2.5 11 1.5 10 0 OFF 10 2 ON/OFF 100 OFF 100 100 BAND NLIN 10 5720F 320G TCJ
0F
Zone 5 Setting
OFF 14 2.7 1.3 1.5 11 0 OFF 10 2 ON/OFF 100 OFF 100 100 BAND NLIN 10 5720F 320F TCJ
0F
SSD RLY 1D2U 1R2R 1N2N 0 0 OFF VAR0 CTA 2 NONE
SSD RLY 1D2U 1R2R 1N2N 0 0 OFF VAR0 CTA 2 NONE
12. Electrical
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13. PNEUMATICS
13.1. Pneumatic Lubrication (For machines with airline lubrication)
As the manufacturers of the Sapac Sealer Closer, Sapac, together with our pneumatic equipment suppliers feel that we should point out the benefits of proper lubrication of the pneumatic prime movers, ie. the pneumatic actuators. With proper lubrication the above mentioned actuator seals can travel at least 3000km without attention. Quote ex Applied Pneumatics International Journal, Volume 11, November 1987, page 12. "At regular intervals we take a cylinder at random from the production line and test the seals to destruction. During the course of these tests, the piston will travel the equivalent of from our factory to Barcelona and back, which means in service you can expect our cylinders to travel at least 3000km without attention". Further we quote from the British Compressed Air Society Code of Practice: "The importance of correct lubrication of pneumatic equipment cannot be over stressed. It decreases friction, reduces wear and prevents corrosion of the moving parts. The most efficient and economical method to lubricate pneumatic equipment is to introduce the oil in droplet form into the air stream. As a general rule use 1 drop of oil (0.02 millilitre approximately) to each 280 dm3 (10 cu ft) of air consumed".
Note:
To put the above into context it is important to qualify it by identifying information as being pertinent to the Oil-Fog type Lubricators only. All Sapac equipment uses Micro-Fog Lubricators. Guidelines for their operational adjustment follows.
The Micro-Fog lubricator passes into its airflow only a small percentage of the oil seen dripping through the sight dome. Because only the finer particles are picked up by this air flow, a drip rate of 10 to 20 times higher than the oil-fog unit described above, will be set when adjusting the Micro-Fog design.
Note:
This gives a recommended minimum drip rate of 10 drops (0.20 millilitre approximately) to each 280 dm3 (10 cu ft) of air consumed. Actual application may vary from this amount but it is a good starting point. Recommended drop rate is 1 drop per 7 machine cycles.
It can therefore be readily seen that lubrication rates need to be referenced to air consumption figures.
13. Pneumatics
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Standard pneumatic lubricating oil (mineral oil, Castrol AWS 32), may be used in all these lubricators. Medical paraffin instead of lubricating oil may be used throughout all lubricators if so desired.
LUBRICATORS MUST BE CHECKED DAILY FOR CORRECT ADJUSTMENT AND KEPT FULL OR PREMATURE PNEUMATIC CYLINDER AND COMPONENT WEAR COULD RESULT.
The Micro-Fog type lubricators are easily identified by a visual check at the adjusting knob situated just above the sight dome. The adjusting knob will be fitted with a red locking ring. In addition to the above and regardless of the colour of the locking ring, the Micro-Fog unit, when in operation can be identified by the ever present cloud of oil vapour sitting above the liquid oil in the lubricator bowl.
Note:
If you have a Micro-Fog Lubricator which is not producing a visible vapour cloud above the liquid oil when the machine is cycling, you must take steps to remedy the situation without delay so as to minimise pneumatic component wear.
Figure 9.1 Norgren Lubricator
13. Pneumatics
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13.2. Pneumatic Schematic

For Pneumatic Schematic Drawings see Appendix A
13.3. Pneumatic Components

.1. Actuators LEVELLER SECTION Item AA AB Description Bag Clamp Cylinder Bag Stop Arm Actuator Qty 2 1 Actuator Type CHANTO D/A Pneumatic Cylinder CM38BX 25SP Kuroda D/A PRN-300-90-40 Actuator
CLEANER SECTION Item CB1 CB2 DB Description Bag Opening Cylinder Dust Extraction Cylinder Cleaner Actuator Probe Rotary Qty 1 1 1 Actuator Type Norgren D/A M/6025/05 Norgren D/A M/6025/75 L Cylinder Cylinder
Norgren Rotary Actuator M/60283/90
CLOSER SECTION Item CB3 Description Closer Flap Cylinder Qty 1 Actuator Type Norgren D/A M/6025/50 FL Cylinder
13. Pneumatics
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.2.
Control Valves CONTROL VALVES (Standard Machine) Item B1 Description 45A-LCC-DACJ-2KD 4/2 Mac Single Solenoid Valve 45A-LCD-DACJ-2KD 4/2 Mac Solenoid Valve with flow controls 712C-14-PE-B12JD 4/2 MAC Single Solenoid Valve 55B-24-RE 3/2 Mac Pilot Operated Valve 55B-14-RA 3/2 MAC Pilot Operated Valve Qty 2 5 1 Actuator Type Leveller Section Cleaner Section Closer Section (at rear) Leveller Section (at rear) Cleaner Section Leveller Section
B2
B3 B4 B5
1 1 1
CONTROL VALVES (D.I.P. Machine) Item B1 Description 45A-LCC-DACJ-2KD 4/2 Mac Single Solenoid Valve 45A-LCD-DACJ-2KD 4/2 Mac Solenoid Valve with flow controls 712C-14-RA 4/2 MAC Single Solenoid Valve 55B-24-RE 3/2 Mac Pilot Operated Valve 55B-14-RA 3/2 MAC Pilot Operated Valve Qty 2 6 1 Actuator Type Leveller Section Cleaner Section (see figure 13.3.5) Closer Section (at rear) Leveller Section (at rear) Cleaner Section Leveller Section
B2
B3 B4 B5
1 1 1
13. Pneumatics
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.3.
Pneumatic Equipment EQUIPMENT Item A1 A2 A3 A4 Description T13-400-E2AD Norgren 3/2 Shut off Tap B64-GNN-KMD3 Norgren Filter/Regulator LO7-200-MPQD Norgren Mico-Fog Lubricator F64-CNN-DMDO Norgren Pure-air Filter RO7-100-RNEG Norgren Pressure Reg 0-3.5 bar 18-013-996 Norgren Pressure Reg LPS 10/2 Compare Pressure Switch ZSM-1-121L S.M.S. Pressure Switch Qty 1 1 1 1 Actuator Type Machine Spine (Rear Centre) Cleaner Section Cleaner Section Cleaner Section (Supply to all pneumatic valves) Closer Section Closer Section Closer Section Closer Section
A5 A6 A7 A8
1 1 1 1
Figure 13.3.1 Main Frame Pneumatic Location
13. Pneumatics
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Figure 13.3.2 Leveller Section Pneumatic Location
13. Pneumatics
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Figure 13.3.3 Cleaner Section Pneumatic Location
13. Pneumatics
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Figure 13.3.4 Closer Flap Pneumatic Location
13. Pneumatics
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Figure 13.3.5-Cleaner Section Valve Stack (Standard Mc)
Valve No. 1 2 3 4 5
Valve Type 45A-LCC 45A-LCC 45A-LCC 45A-LCC 45A-LCC
Valve Duty Vacuum ON/OFF Pilot Valve Dust Extraction Cylinder Directional Valve Bag Opener Cylinder Valve Cleaner Probe Actuator Directional Valve Bag Clamp Cylinder Directional Valve
13. Pneumatics
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14. TROUBLESHOOTING & MAINTENANCE

14.1. Levelling Mechanism 14.1.1. Troubleshooting
The levelling mechanism, as with all other mechanisms on the Sapac Sealer Closer should operate relatively trouble free. There are however some problems which can re-occur especially if the dust extraction at the leveller section is inadequate or if the packing machine is not fitted with a genuine Sapac Bag Clamp.
Warning:
Read Safety Section 5 before any maintenance or adjustments are carried out Stop machine and disconnect power supply before servicing or repairing. Maintenance and adjustments must be performed with all power supply disconnected unless otherwise specified in this manual. High-pressure air systems are dangerous. Do not service or trouble-shoot systems with air supply on. Be sure to bleed off any trapped air before working on components since it is possible to have high pressure trapped in airlines.
FAULT:
THE BAG POPS BACK UP AT ONE END OR THE OTHER AFTER LEVELLING Cause Solution Check for powder contamination.
Carrier Belt Guide Slide is

contaminated product. with Powder
Springs have weakened through high cycle fatigue.
Check by hand that the front belt guide is free to move back against its return springs and that they have enough compression to return the guide to its drive position i.e. hard against the compression belts. length. Check the uncompressed spring Uncompressed spring length should be 80mm or more.
14. Troubleshooting & Maintenance
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FAULT:
FOLDS
Bag Fold Tapered/Uneven Levelling height different heights photocells at
Over-Levelling Levelling height photocells to low
Under-Levelling Levelling height photocells to high
Good Fold
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14.2. Levelling Mechanism 14.2.1. Maintenance

For correct functioning of the leveller, ensure that the photo cells are kept clean. Powder build-up on their faces will reduce efficiency. Operator care of the photo cells is outlined on Section 8.1.3. The sensitivity of the photo cell should not need adjusting. If adjustment appears necessary, first check that the photo cell face is clean. If it is found that adjustment is required, this is carried out on the amplifier to which the photocell is connected, via its fibre optic cable. The amplifiers are located nearest to the infeed end of the machine, next to the valve stack. A slotted sensitivity adjustment is on the face of each amplifier. Details on amplifier type and setting are covered in the Appendix. Basically the sensitivity should be such that every bag entering the machine and passing the face of the photocells must be detected. The photocells are each mounted on a small stainless steel plate with 2 x M6 cap screws. The plate is slotted to allow for height adjustment to ensure bags are levelled to the correct height. Once the height is determined it should not need altering.
Figure 14.2 Photo Cell Diagram
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14.3. Cleaner Mechanism 14.3.1. Troubleshooting

Because of its nature (vacuum cup adhesion) the Cleaner Section Operation is undoubtedly the most temperamental aspect of the Sapac Sealer Closer. There are several reasons why the opening and cleaning of the bag seal area should be difficult. Stepped pattern of the bag top often leads to unavoidable undulations in the area of vacuum cup contract. Limited adhesion force of the vacuum cup i.e. negative 1 atmosphere x vacuum cup contact area (small due to physical restrictions). From necessity a sensitive, lightly constructed, vacuum cup guidance system (slide).
However, there is no reason that we are so far aware of, why a properly adjusted and maintained Bag Cleaning Mechanism cannot work as reliably as the rest of the machine provided that bag construction falls within our recommended Users Bag. FAULT: VACUUM CUP FAILS TO ADHERE TO OR FOLLOW BAG ie CLEANER PROBE UNABLE TO ENTER BAG TOP Cause Solution Replace damaged vacuum cup.
Vacuum cup damage due to wear or improper installation
Ascertain reason for cup damage in order to prevent future damage. Check for build up of product on the shafts causing sticking. Check that the silicone vacuum supply tube is not restricted in its movement. Check that the vacuum cup holder return spring is at its rest position Check that the vacuum generator is functioning correctly Check that vacuum valve is functioning correctly. Check that the vacuum on output is present at the vacuum valve pilot solenoid.
Vacuum cup slide movement encumbered.

Low Vacuum.
Bag opening malfunctioning
cylinder
is
Check for seal failure or physical damage. Check for tightness at cylinder pivot points. Check for tightness in main pivoting block bushes to which sliding shafts are mounted.
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Check that the vacuum switch is adjusted properly.
Note:
Care should be taken when fitting new vacuum cup slide springs not to stretch the springs as this would increase their compressive strength making it difficult for the cup slide to operate correctly. Doing this will cause the cup to break free when the bag is pulling it along while opening the bag top. This will cause cleaner errors. Only light spring tension is required when the shafts are clean and everything else is working, as it should.
Figure 14.3 Cleaner Mechanism
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14.4. Heating Dies 14.4.1. Troubleshooting

Heating Die malfunction is a possibility from both mechanical and electrical points of view. Mechanically, seals may be affected through misalignment of the front heating dies while electrically, seals may be affected from an over or under heat condition of the die itself.
FAULT:
HEAT SEALS ARE NOT UNIFORM IN WIDTH OR OF INIFORM TEXTURE, ARE INCOMPLETE OR CLEAR Cause Solution A quick check of the Fuse Failure L.E.D. labels on the Field Zone Control boxes mounted on the rear of the machine spine will indicate whether failure of two or more dies is from a blown fuse (see The Field Control Boxes Section 9.1.3). Other electrical causes for Heating Die failure could be an open circuit cartridge element or lead. To check out get an electrician to do a voltage check across the cartridge element terminations ie. When the Temperature Controller Output L.E.D. is ON (see Section 9.1.2) there should be 220 Volts (more or less) across each cartridge element. If no evidence of electrical failure is present it could be possible that die pressure adjustment has been carried out wrongly ie. Too much pre-tension on the front Heating Die springs will tend to roll the Die Profile downwards out of parallel with the back Die profile.
Two or more Heating Dies are failing to reach set point temp.
The front dies are parallel to the rear vertical plan ie. Top heating die profile more pressure then edge.
not sitting dies in the edge of the is exerting the bottom
Note:
One probable cause of rolling is that when initially pushing the die faces together, there has been too much pressure applied. It is important that the faces only just touch. See Section 9.1.4 for Heating Die Adjustment.
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FAULT:
BAG OUTER PLY IS BEING SCORCHED ie BROWN TRACKS WHERE THE BAG HAS BEEN IN CONTACT WITH THE HEATING DIE PROFILE Cause Solution If the Temperature Controller digital displays all check out O.K. See Section 7.2 switch OFF the Sealer Heat ON/OFF switch, on the operators control panel, and have an electrician check out the Field Boxes (see Section 9.1.3).
The above can only be caused by overheated dies. Assuming that the machine is running at recommended die temperatures. (See temperature controllers on operators control panel) this problem can be caused by one of the Heating Cartridge Element leads going to ground.
Note:
The thermocouple carrying the Heating Die will always indicate a fault specific to itself on the Operators Control Panel i.e. Alarm Indicator Lamp ON for over or under under heat or Temperature Controller digital display of thermocouple fault conditions.
14.5. Seal Compression Wheels 14.5.1. Troubleshooting

FAULT: THINNED WEAKENED SEAL Cause Too much pressure at the Seal Compression wheel. FAULT: Solution For operator adjustments see Section 9.2.
SELA OBSERVED AS MOTTLED PATTERN OF CLEAR AND OPAQUE PATCHES ALONG THE SEAL LINE. Cause Solution For operator adjustments see Section 9.2.
Provided that Heating Dies are all operating, then the cause would be lack of pressure exerted from the Seal Compression wheels.
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14.5.2. Maintenance
Maintenance of the Compression Wheels is not generally required, however if after the correct gap procedure is carried out and it is found that seal compression is not being achieved (See Section 10) we would advise a visual inspection of the Compression O Rings (D) is required (See Figure 14.5). To inspection the O ring (D) remove M6 bolts (A) and lift retaining ring (B) and moving ring (C) to expose same. Should replacement appear to be necessary the Heartbeat sensor/chain tensioner bracket, and rear drive transfer chain, must be removed (See Figure 14.7).
Figure 14.5 Seal Compression wheel diagram
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14.6. Seal Scoring Wheels 14.6.1. Troubleshooting

FAULT: SEAL NOT BEING SCORED PROPERLY Cause Improper adjustment of scoring pressure Heat seal not of high enough standard to accomplish the scoring operation. Solution For operator adjustments see Section 9.3. Refer to Heating Dies Troubleshooting Section 14.4.
14.6.2. Maintenance
As for Seal Compression Wheels maintenance section 14.5.2.
Figure 14.6 Seal Scoring Wheel Diagram
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14.7. Seal Compression/Scoring Wheels Drive Chain 14.7.1. Maintenance

Visual inspection from time to time of the drive transfer chain is advised.
The chain drive transfer of the Compression/Scoring Wheels can be reoccurring maintenance concern if the chains are left to run un-lubricated throughout the season.
Note:
Figure 14.7 Drive Transfer Chain Diagram
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14.8. Bag Top Closer 14.8.1. Troubleshooting

FAULT: LEAD EDGE OF FOLD FOLDED BACK Cause Fold guides too tight Excessive adhesive build-up. Solution
For operator adjustments see Section 10. Clean fold guides of adhesive build up.
FAULT:
UNEVEN FOLD WITH BOWED BAG TOP Cause Solution
Fold guides too loose
For operator adjustments see Section 10.
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FAULT:
CLOSER AIR PRESSURE IS ADJUSTED TO RECOMMENDED LEVEL (AROUND 20 PSI) BUT ADHESIVE ON BAG CLOSURE FAILS TO ADHERE TO THE OUTSIDE OF THE BAG Cause Solution Check bag for excessive powder contamination
Excessive powder contamination of the adhesive or bag outer in the closure area. Failure of the Air Heater Element to heat its transient air.
Check Temperature Controller set-point, see Sapac default settings Section 12 Check that the Temperature Controller is functioning ie. digital display is not indicating a thermocouple failure and that the output L.E.D. at the top left hand corner of the display is flickering. Check for a blow line fuse at the Field Control Box (see Section 9.1.3) mounted on the rear side of the Sealer spine at the Bag Top Closer Location (Zone 5). Check the Air Heater element for open circuit condition by opening the Field Control Box and doing a voltage check across the element leads. Voltage across the leads should be 415 volts A.C. (more or less).
14.9. Air Heating Element

The air heating element is housed in a stainless steel tube (body).
14.9.1. To remove the element

Ensure power is off before any attempt is made to remove the Air heating Element Work must be carried out only by a qualified electrician.
Warning:
Remove rear cover behind control Remove element wires from terminals on solid state relay Field Control Box. Release both gland nuts from each end of spring conduit on entry to cable glands (A) cut cable ties (if used). Remove element retaining M6 cap screw, which is threaded into the end fitting (B). Draw element from heater body by pulling back on end fitting (C).
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Remove conduit and gland nuts from element wire.
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14.9.2. To replace the element

Thread conduit and gland nuts back over new element wire. Follow steps for removal (Section 14.9.1) in reverse order.
Figure 14.9 Air Heating Element
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14.10. Drive Train 14.10.1. Troubleshooting

FAULT: THE AUDIO BUZZER IS ALTERNATING ON AND OFF. THE EMERGENCY STOP IS UNLATCHED BUT THE START/STOP PUSH BUTTON SWITCH FAILS TO START UP THE DRIVE MOTOR Cause The Closer air pressure is below the set point of the Closer Air Pressure switch. One or other of the main drive motors has tripped out on overload ie. The Sealer drive or Conveyor drive motor. The Drive Run encoder is not being driven properly after disturbance to its support bracket during maintenance on the Seal Scoring/Compression mechanism OR is not plugged. The Sealer drive Electronic speed controller has gone down with a fault. Solution Check the air supply Check the Closer Air Pressure switch Set Point Reset the drive motor, checking for any possible causes
Check the position of the encoder and that it is plugged in. See Section 14.10.2
Check the Sealer Drive Electronic speed controller in the electronics cabinet for any error messages.
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14.10.2. Drive Run Encoder

A pulse encoder is used as a PLC Input. This enables us in conjunction with the bag too low Photo Electrical microswitch protocol, to track the bag movement through the sealer. An auto tune program enables us to centralise the bag in the leveller. Enter and exit the cleaner probe at the correct time and open and close the closer flap at the correct time. A dirty bag too low photo cell belt slippage can effect the auto tune function.
Figure 14.10.2 Drive Run Encoder
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14.10.3. Troubleshooting
Has there recently been any maintenance work carried out on the Seal Scoring Compression mechanism? No Is the Closer air pressure below 15psi? See air pressure switch setting Page E5. Make sure that the Drive Run Encoder is plugged in and that the drive coupling is secure Yes Make sure that the main air supply, at the A.S.U. on the rear of Sealer spine is turned on then adjust the Closer air pressure to around 20 psi if necessary. Yes
Yes
Yes
No Push the drive start push button (twice if necessary). Does the Sealer Drive start-up and run? No
Yes
PROBLEM SOLVED Yes
Go to the Low Voltage Electrical Cabinet (L.H. Cabinet) at the rear of the machine and operate the red overload push button switch at the top left hand corner next to the Speed Controller calibrated dial. Now push the start push button (twice if necessary). Does the Sealer Drive startup and run? No Has there recently been any maintenance work carried out on the Open Gear transmission or have the Closer Section Carrier belts been replaced or tensioned. No Have an Electrician check out the Electronic speed controller in the High Voltage section of the Electrical Control Cabinet. Yes Check that proper adjustment procedures have been followed according to the following Pages M19 to M25.
Yes
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14.10.4. Gear Motor and Open Gear Transmission

The Sealer drive train starts with a geared motor driving through an open four (4) gear transmission. Geared motor type is S.E.W. EURODRIVE. Motor speed control is by AC adjustable Electronic Frequency Drive.
Depending on site specific requirements, your Sealer/Closer could be fitted with one of several differant drives, it is necessary to open the High Voltage electrical cabinet at the rear of the machine for final identification.
Note:
The open drive gears need no maintenance apart from the backlash adjustment between the nylon primary driven gear C and the steel idler gear B refer to Figure 14.10.4. This adjustment is, needless to say, factory set prior to delivery and only needs to be carried out after closer section V Belt tensioning, gear replacement, or gearbox removal. Following is a chart giving the specification of each gear as illustrated on Figure 14.10.4. Gear Designation A B C D Material Nylon Steel Nylon Nylon Driver Idler Primary Driven Secondary Driven Function Gear Data M=3 T = 43 PA = 200 O.D. = 136 P.C.D. = 130
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Figure 14.10.4 Drive Train
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14.10.5. Adjustment of the Open Gear Transmission

The drive gear and two driven gears are manufactured from Nylon (plastic) for long life and quiet smooth operation requiring no lubrication. While there is minimal thermal expansion, correct backlash is important for long gear life, as the gears are subject to heat from their own action and from the reactivation air heater.
Check the backlash improper backlash will cause failure. Check the backlash on installation and after carrier belt adjustment, each 90o through 1 full gear rotation.
Note:
Correct Backlash is: 0.24mm 0.381mm (0.010 0.015)
The idler (B) and main drive gear (A) are factory set for backlash. See Figure 14.10.4. These do not need altering. The idler gear is freewheeling and is mounted to a shaft, which is bolted to the gearbox/drive motor mounting plate. The mounting plate is slotted and held on by nuts over studs fixed to the main frame, after loosening mounting plates (M10) it is possible to move the drive gear/idler assembly to alter the clearance/backlash of the idler (B) and driven gear (C) us 17mm open ended spanner.
1. Whenever the Closer Section carrier belt tension is adjusted using the tension adjusters at the drive end of the machine, it will be necessary to adjust the idler (B) and driven gear (C) backlash. 2. Always adjust the carrier belt tension at the drive end an equal amount for both front and rear belts. If this is note done, the backlash between driven gears (C ) and (D) will not be correct.
Note:
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Driven Gears (C ) and (D) should always be at 130mm centres (see P.C.D.). ADJUSTMENT OF THESE CENTRES IS NOT NORMALLY NECESSARY AS THEY ARE FACTORY SET. However, when the setting is correct the two bedplates onto which the Compression assembly is mounted should be 20mm apart. The gear shafts are held parallel and at the correct centres by flanged bearings at the top, and their mountings at the bottom. Adjustment of the Driven gear centres is possible as follows. To adjust the Driven gear centres, the capscrews holding the compression assembly bed plates to the machine chassis must first be loosened (E and F, Figure 14.10.5) (front and rear bed plates) four M8 cap screws. Next the flange bearing M10 Hex bolts (G) may be loosened prior to prising the said base plates and flange bearings apart or closing them together.
Be sure to tighten all bolts/screws after ANY adjustment has been made. Adjustments are not completed until this is done.
Note:
Figure 14.10.5 Open Gear Transmission Adjustment
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14.11. Carrier Belts 14.11.1. Adjustment

As there are three sets of carrier belts, and three sets of adjustment. Carrier belt tension is critical to ensure correct transmission of the drive without belt slip. Belt slip will cause variations in carrier belt speed and hence bag speed which not only affects relative speeds from one set of belts to the next, but also relative speeds between carrier belts and the conveyor belt. Insufficient carrier belt tension will also result in a variation in speed due to loading dependent upon how many bags are within the machine at a given time.
14.11.2. Primary Carrier Belts

The Drive Train is continued from the Open Gear Transmission through the Driven Gears (C ) and (D) (See Figure 14.10.4) and their gearshafts to the Closer Section Carrier Belts under the compression assembly. Adjustment: Referring to Figure 14.11.2 adjustment of these belts is as follows: Loosen M8 cap screws at outer end (E) of the compression section and loosen M8 cap screw (F) in slot. Adjust tension using M10 cap screw (H). It will be necessary to loosen locking nut (I) with a 17mm open-ended spanner before cap screw (H) can be adjusted. Be sure to tension both belts an equal amount so as the V pulley shafts remain in line with each other as this affects gear mesh. Retighten all bolts, cap screws and locknuts when tensioning is complete, making sure driven gears (D) and (C) are at 130mm centres also outlined on Section 14.10.5. Correct belt tension is indicated by SAG of the carrier belt in the horizontal plane of approximately the belts own width.
CORRECT SURFACE SPEED OF CARRIER BELTS IS CRITICAL TO PRODUCING GOOD SEALS. SOME BRANDS OF B-SECTION BELTS DIFFER IN CROSS SECTION, AND SURFACE SPEED ALTERS ACCORDINGLY.L USE ONLY CONTINENTAL BRAND SPB BELTS.
Note:
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Figure 14.11.2 Primary Carrier Belt Adjustment
Note:
Do not over tension belts. Correct tension is when belts have some SAG up to their own width.
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14.11.3. Secondary Carrier Belts

The Secondary Carrier Belts extend from the compression wheel through to the outfeed end of the leveller section. Drive is transmitted from the Primary Carrier Belt (Closer Section Carrier Belt) to the Secondary Carrier Belt (Heat Sealing Section Carrier Belt) via Chain drive and the compression scoring wheel drive shafts. The tension adjustment for these secondary belts is located at the outfeed end of the leveller section. Adjustment: Referring to Figure 14.11. adjustment of these belts is as follows: To adjust the double pulley position the M20 shaft nut (A) must be loosened. To do this a socket (30mmAF), short extension and ratchet driver are required. Once the shaft nut is loose, adjustment is done with the 2 x M12 (B & C) nuts, one each side of the bulkhead plate. A 19mm open-ended spanner is best for this. Once belt is tensioned, retighten all nuts. Both carrier belts should be tensioned to approximately the same amount. This can be gauged by the amount of threaded shaft sticking through the bulkhead.
Whenever this adjustment is made, it is necessary to re-tension the leveller section (Final) carrier V-Belts as they will slacken off.
Note:
Figure 14.11.3 Secondary Carrier Belt Adjustment
Note:
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1492LS09.DOC 14.11.4. Final Carrier Belt Adjustment
Final Carrier belts extend through the leveller section to the Infeed Nip pulleys. Drive is transferred to the Final Carrier belt (the Leveller Section Carrier Belt) via the double V pulleys (Figure 14.11.3). The Final Carrier belt tensioners are located externally outboard of the sealer spine. See Figure 14.1.4. Adjustment: The tensioners are in the form of 2 x 10mm rods, fixed directly to the infeed pulley shafts at one end. The other end of these rods is threaded and passes through the first stainless steel bulkhead. There is a nut (M10) either side of this bulkhead. These are the adjuster nuts (A & B).
Before adjusting it is necessary to loosen the pulley shaft dome nuts (C) (M12) at the other end of the adjuster shaft, to enable the pulley shaft to slide. It may be necessary to loosen these pulleys quite a lot before they slide freely.
Note:
Adjust the belts by screwing the M10 nuts (A & B) either side of the bulkhead in the appropriate direction using a 17mm open ended spanner. Retighten all nuts after adjustment.
While infeed pulleys are loose, they will tend to tilt inwards, loosening the carrier belt still further. Be sure not to overtighten the belt, because of this. Make allowance for the pulleys returning to horizontal when tensioning. Do not attempt to adjust the tension of the belts without loosening the pulley shaft nuts sufficiently to allow free sliding, or the adjuster shaft will bend.
Note:
Figure 14.11.4 Final Carrier Belt Adjustment
Note:
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1492LS09.DOC 14.11.5. Carrier Belt Identification

Location Closer Section Heat Sealing Section Levelling Section Drive Function Primary Secondary Final
Continental SPB Type SPB4500 2 off SPB4500 2 off SPB2360 2 off
14.12. Conveyor
The conveyor belt tension and alignment has been set by the manufacturer prior to delivery and no adjustment should be necessary initially. However, through general wear and tear some stretching may become evident and adjustment may be necessary to prevent untimely damage or slippage.
14.12.1. Tensioning
To increase conveyor belt tension, (refer Figure 14.12) from both sides of the conveyor first loosen nut A and bolts C (2 per side) then tighten nuts B. The tension on both front and rear sides of the belt must be such that it tracks to the centre of the tensioning roller. Re-tighten bolts C and then lock nut B in position with nut A.
14.12.2. Tracking Tail (Idle) Rollers

To track the belt toward the rear of the conveyor, on any of the above rollers, either of the following adjustments must be carried out: (refer Figure 14.12) Either: Adjust the front tracking adjustment. First loosen nut E and bolts D (4 per side) then tighten nut F. The tension on both front and rear sides of the belt must be such that it tracks to the centre of the tensioning roller. Re-tighten bolts D and then lock nut F in position with nut E. If the belt is already tensioned to the point of being a concern, (tail rollers only) alter the rear tracking adjustment by loosening nut E and bolts D, then back off nut F so that the tensioning roller moves towards the driver roller. Re-tighten bolts D and then lock nut F in position with nut E.
Or:
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14.12.3. Tracking Drive Roller

(refer Figure 14.12) To track the belt towards the rear of the conveyor, loosen nut F then bolts D and then slowly tighten nut E. Re-tighten bolts D and then lock nuts E and F hard against the anchor lug. To track the belt towards the front of the conveyor, loosen nut F then bolts D and slowly tighten nut E. Re-tighten as above.
14.12.4. Belt Replacement

Total conveyor belt replacement, unlike adjustment, involves the removal/replacement of the conveyor front panel as follows: (refer Figure 14.12) 1. Remove bolts C & D and G I, in alphabetical order. 2. Loosen grub screws in bearing collars, 2 each. 3. Remove front panel. 4. Remove and replace conveyor belt, confirming conveyor direction with arrow on belt. 5. Align head and tail drums with their bearings and the idle (tension) roller with its bolt hole. 6. Replace front panel. 7. Replace bolts in reverse order to removal. 8. Belt will require tensioning and tracking adjustment, refer to previous pages.
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14.12.5. Lubrication
The mechanical components requiring lubrication are: 1. Electric Motors As is typical, the motors are fitted with single row, deep groove radial pre-greased ball bearings. No additional lubrication is therefore necessary.
Each geared motor and each gear unit is dispatched from the manufacturers works with the specific mounting position quantity of lubricant, unless other arrangements were agreed to. Without being specially specified otherwise in the order, the gear units will be provided with the lubricant as follows. Motor/Gearbox mounting position: H2 = 1.1 litres Use Mobil gear oil 636 or Shell Omala 680
Note:
2. Bearings The UC, bearing units are grease lubricated and are basically to be relubricated as conditions demand. For lubrication it is recommended to supply the grease during operation of the Bearing Units so as to avoid excessive greasing. Where environments are clean and operating temperatures do not rise high, replenishment of grease may not be necessary, however, where environment is dirty or dusty, a monthly supplementary lubrication is recommended. Shell Alvania Grease 3 or equivalent is required.
Conveyor Mechanical Components ITEM 1 2 3 4 DESCRIPTION SEW SA57DT80N4 0.75kW 19.2rpm 480 Volt 3 phase 60HZ electric motor UCF 204-20 Flange bearings UCF206-30 Flange bearings AELRPP 204-20 Pillow Block QTY 1 4 2 2 LOCATION Conveyor Driver Roller Tail Rollers Drive Roller Tension Roller
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Figure 14.12 Conveyor Tensioning
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15. SPARE PARTS

15.1. Spare Parts Requirements
The Sapac Sealer Closer requires a minimal amount of spares. There are however, some important consumable spares (essential spares, see Section 15.3) which should be carried in stock at all times, to avoid plant downtime. Consumable spares are much like tyres on a car. They wear out and need replacing periodically. Non-consumable spares (recommended Spares, see Section 15.4) which Sapac consider should be carried, are also listed. In normal operation, these parts may never be needed, but act as insurance in the case of an after hours failure or the parts carried by Sapac being unavailable due to prior sale.
15. Spare Parts
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15.2. Illustrated Spare Parts 15.2.1. Leveller And Closer Section
Infeed Nip Item Number A B C D Part No. 8450010 8420092 8420090 8360059 Description Infeed Carrier Belt Pulleys Leveller Roller Bed (Front) Leveller Roller Bed (Rear) Infeed Pulleys Bearings #No Per Machine 2 1 1 4
15. Spare Parts
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Leveller Section Item Number A B C D E F G H Part No. 8710008 8320215 855008 8550014 164157 8180002 8170001 8430083 8430080 Description Leveller Carrierbelt Springs Clamp Cylinders Leveller Drive Chain 400mm Connecting Link Electric Leveller Motor Leveller Roller Needle Bearing Leveller Roller Needle Seal Front Leveller Belt UHMW Guides Rear Leveller Belt UHMW Guides #No Per Machine 3 2 2 2 2 8 8 2 2
15. Spare Parts
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Cleaner Carrier Belts Item Number A B C D Part No. 8520005 8450012 8120010 8520020 Description Leveller Section Carrier Belts Double V Pulley Double V Pulley Bearings Cleaner/Heat Belts Sealing Section Carrier #No Per Machine 2 2 4 2
15. Spare Parts
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Cleaner Vacuum Section Item Number A B C D E Part No. 8390011 8390010 8350009 8430094R 8341020 8710002 Description Vacuum Filter (Complete) Vacuum Filter Element Vacuum Cups Vacuum Cup Slide Block Silicon Vacuum Hose (with Spring) Vacuum Cup Return Springs #No Per Machine 1 1 1 1 1 2
15. Spare Parts
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Cleaner Probe Section Item Number Part No. Refer Sapac A B 8318046 8410363 Description #No Per Machine Cleaner Probe Assembly (Includes Parts 1 Below) Rotary Actuator Air Blast Probe 1 1
15. Spare Parts
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Cleaner Cylinder Section Item Number A B C D Part No. 8150002 8320200 8320186 8140004 Description Vacuum Slide, Pivot Bushes Air Cylinder For Vacuum Cup Air Cylinder For Dust Extraction Cylinder Rod Ends #No Per Machine 1 1 1 2
15. Spare Parts
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15.2.2. Heat Sealing Section
Sealing Dies Item Number A B C D E Part No. 163033 4140001 8490006 4060027 8490008 4060027 8720002 Description Heat Sealing Cartridge Thermocouples R.H. Heating Die c/w Element Element only L.H. Heating Die c/w Element Element only Heating/Cooling Die Mounting Spring #No Per Machine 6 3 3 2 3 2 4
15. Spare Parts
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Compression & Scoring Wheels Item Number A B C D E F Part No. 4010055 8550002 8550006 8420126 8420128 8450008 Description Rotary Encoder Chain Tensioner Drive Chain Chain Drive Sprockets (Thick) Chain Drive Sprockets (Thin) Heat Sealing & Closer Section Carrier Belt Pulleys #No Per Machine 1 2 2 2 2 4
15. Spare Parts
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15.2.3. Bag Top Closer Section
Bag Top Closer Item Number Part No. { 4060009 { { B C 4140001 8320185 Description Air Heat Element Complete (NZ 400V) Air Heat Element Complete (USA, AUST 460V) Air Heat Element Complete (USA 480V) Thermocouple Closer Flap Air Cylinder 1 1 1 1 #No Per Machine
15. Spare Parts
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Compression Assembly See Parts List Over
15. Spare Parts
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Compression Assembly Item Number A B C D E F G H Part No. 8530012 8450044 8450008 8120008 8120013 8420174 8420172 8710006 Description Compression Belts (White) Compression Belt Drive Pulley Heat Sealing & Closer Section Carrier Belt Pulleys Compression Belt Pulley Bearings Compression Belt Drive Pulley Bearings Front Compression Belt 2 Roller Sprung Assembly Complete Rear Compression Belt 4 Roller Fixed Assembly Complete Return Spring Front Compression Belt Assembly #No Per Machine 2 2 2 6 2 2 1 4
15. Spare Parts
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15.2.4. Drive Assembly
Drive Assembly Item Number A B C D E F Part No. 8430015 8420001 8120013 8110004 8520015 8610025 Description Drive Gear Idler Gear (Metal) Idle Gear Bearing Pulley Bearing Closer Section Carrier Belts Drive Motor Gearbox (SEW) #No Per Machine 3 1 1 2 2 1
15. Spare Parts
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15.2.5. Belt Rollers
Leveller Roller Plate Assembly Item Number A B C D E Part No. 8420096/97 8420098/99 8430053 8420084 8420089 8420090 8420092 Description Fixed Roller Mount Plate (R/H or L/H) Spring Roller Mount Plate (R/H or L/H) V Belt Rollers Roller Pins Step Washer Leveller Roller Assembly Fixed (R/H or L/H) Leveller Roller Assembly Sprung (R/H or L/H) #No Per Machine 1 1 12 12 4 1 1
15. Spare Parts
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Rear Belt Roller Bed Assembly Item Number A Part No. 8420083 8420082 8420080 Description Carrier Belt Roller Bed - 5 Roller Assembly Carrier Belt Roller Bed - 4 Roller Assembly Carrier Belt Roller Bed - 3 Roller Assembly #No Per Machine 1 4 1
15. Spare Parts
Page 15 of 21
1492LS09.DOC
Front Belt Roller Bed Assembly Item Number A Part No. 8420072 8420070 8420068 B C 8420086 8710004 Description Carrier Belt Roller Bed - 5 Roller Assembly Carrier Belt Roller Bed - 4 Roller Assembly Carrier Belt Roller Bed - 3 Roller Assembly Step Washer Carrier Belt Roller Bed Clamp Springs #No Per Machine 1 4 1 16 12
15. Spare Parts
Page 16 of 21
1492LS09.DOC
General Item Number Part No. 8320130 Description Gas Stays for Lids (Doors) Bearings (Specify Sealer Type & Brg Location) 8630004 8170005 8430053 8420084 Bag Stoparm Actuator (PRN300D-90-40) 1 Sealing & Compression O Rings V Belt Rollers (Not Leveller) Roller Pins (Not Leveller) 1 2 48 48 #No Per Machine 3
Electrical Item Number Part No. 4040019 4140029 4140030 4020001 4330023 4330010 4350006 4350005 4230009 Description Temp. Controllers CAL3200 Photo Eye Fibre Optic Cable FEF.PAD.6M Photo Eye Sensor Amplifier FE7C.FRF6. Element, LED Fuse Status Card Solid State Relays Relay: Two Pole 24 Vac Fuse: 3 amp Ceramic Fuse: 5 amp Ceramic Cleaner Error Alarm Buzzer #No Per Machine 4 3 3 4 9 5 16 4 1
15. Spare Parts
Page 17 of 21
1492LS09.DOC
Part No.
162947
Description
1/8 BSP 4/2 Mac Solenoid Valve
Pneumatic Valves Option D.I.P.

45A-LOO-DACJ2KD -
Option -Universal
45-LOO-DACJ-2KD
#No Per Machine

8 7
8310076
3/8 BSP 3/2 Mac Pilot opp Valve 3/8 BSP 3/2 Mac Pilot opp Valve
1
45A-LCD-DACJ-2KD 55B-14-RA 712C-14-RA 712C-14-PE-B12JD
1
1
164196
BSP 4/2 Mac Solenoid Valve
Note:
UL listed valves are used in some states of America. Please state if UL versions are required when ordering. Listed below are standard valve options.
15.3. Essential Spare Parts
Cleaner Section Item Number Part No.

8350009
Description
Vacuum Cup
#No Per Machine

10
Closer Section Item Number Part No. 8530012 Description Compression Belts (White) #No Per Machine 2
15. Spare Parts
Page 18 of 21
1492LS09.DOC
15.4. Recommended Spare Parts
Note:
The recommended spare parts listing that follows is for additional parts to those which are considered essential ie. those parts already listed above. Recommended spares are optional at the clients discretion, and should be ordered depending on such factors as: Number of shifts/day that m/c operates, locality of installation site and site policy on spares stockholding.
Leveller Section Item Number Part No. 8340150 8340159 8710008 8550008 4140029 4140030 8520005 Description Bag Clamp Pneumatic Cylinder Kits RKCM30 Bag Stoparm Actuator Kits Carrier Belt Clamp Springs Leveller Drive Chain Photo Electric Eyes (Fibre Optic) Photo Electric Amplifier Carrier Belts SPB2360 #No Per Machine 2 1 3 2 2 1 2
Cleaner Section Item Number Part No. 8710002 8340015 8341020 8390010 Description Vacuum Slide Springs Vacuum Cup & Dust Extraction Pneumatic Cylinder Kits Silicone Vacuum Hose & Spring Piab Filter Element #No Per Machine 2 2 1 1
15. Spare Parts
Page 19 of 21
1492LS09.DOC
Heat Sealing Section Item Number Part No.

4010055 4330001 4140001 4060027 8490008 8720002 8550002 8710004 8550006 8420126 8420128 8520058
Description
Rotary Encoder Solid State Relay Thermocouple Element L.H. Heating Die C/W Element Heating/Cooling Die Mounting Springs Transfer Chain Tensioner Carrier Belt Clamp Springs BS-08-1 Drive Transfer Chains Drive Transfer Sprockets (Tall) Drive Transfer Sprockets (Short) Carrier Belts SPB2470
#No Per Machine

2 2 2 1 12 2 18 2 2 2 2
Closer Section Item Number Part No. 8520015 See Heat Sealing Section 4060009 See Cleaner Cylinder 8310132 Description Carrier Belts SPB3350 Carrier Belt Clamp Springs #No Per Machine 2 -
Air Heat Element NZ400V USA 460V Closer Flap Pneumatic Cylinder Kit Air Pressure Switch 1 1
15. Spare Parts
Page 20 of 21
1492LS09.DOC
General Section Item Number Part No. 4350003 4350006 4350005 8310126 8340118 8340121 4040019 Description Fuse 2 amp N.B. Fuse 3 amp Ceramic Fuse 5 amp Ceramic MAC-55B Pilot Adaptor MAC-55B Vacuum Spool Kit K55002 MAC-55B Pressure Spool Kit K55001 CAL/3200 Temperature Controller #No Per Machine 10 10 4 2 Pair 1 1 1
15. Spare Parts
Page 21 of 21
1492LS09.DOC
16. APPENDIX A
16.1. Pneumatic Circuits
See attached folded drawing Pneumatic Schematic SCCO-090
16. Appendix A
Page 1 of 1
1492LS09.DOC
16. Appendix A
Page 1 of 1

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1492LS09.

OPERATION AND MAINTENANCE

SAPAC SEALER CLOSER MODEL 41B DFA - EL PASO

1492 LS09 1492LS09

OPERATION AND MAINTENANCE

OPERATION AND MAINTENANCE

OPERATION AND MAINTENANCE

Start up And Operation................................................................................... 6-1 6.1. 6.2. 6.3.

Control System ................................................................................................. 7-1 7.1. 7.2. 7.3.

Leveller And Cleaner...................................................................................... 8-1 8.1. 8.2.

Heat Sealing ...................................................................................................... 9-1 9.1. 9.2. 9.3. 9.4. 9.5.

OPERATION AND MAINTENANCE

OPERATION AND MAINTENANCE

REVISION CONTROL SHEET

1. Revision Control Sheet

OPERATION AND MAINTENANCE

SCOPE AND INTENDED READER

2. Scope and Intended Reader

OPERATION AND MAINTENANCE

ABBREVIATIONS AND DEFINITIONS

3. Abbreviations and Definitions

OPERATION AND MAINTENANCE

OPERATION AND MAINTENANCE

General Safety Procedures.

The following conventions are used in Colby manuals:

OPERATION AND MAINTENANCE

OPERATION AND MAINTENANCE

OPERATION AND MAINTENANCE

START UP AND OPERATION

6. Start up And Operation

OPERATION AND MAINTENANCE

Figure 6.2 Right to Left Feeding Machine

6. Start up And Operation

OPERATION AND MAINTENANCE

Operating Instructions 6.3.1. Start Up

6. Start up And Operation

OPERATION AND MAINTENANCE

6.3.2. Operator Adjustments

6.3.3. Bag Presentation

6. Start up And Operation

OPERATION AND MAINTENANCE

MAX. BAG HEIGHT MIN.

6.3.4. Machine Height

6. Start up And Operation

OPERATION AND MAINTENANCE

6. Start up And Operation

OPERATION AND MAINTENANCE

6.3.5. Line Start-Up Check List

Source right size bag. See Section 6.3.3.

Make adjustments. See Section 6.3.4.

Synchronise Carrier Speed. See Section 6.3.2.

Wait for alarm lamps to extinguish.

Do Seal/Closure Test. See Section 6.3.1.

Remedy prior to starting up Packing Machine.

6. Start up And Operation

OPERATION AND MAINTENANCE

6. Start up And Operation

OPERATION AND MAINTENANCE

OPERATION AND MAINTENANCE

The Switch Buttons and Indicator Lamps

OPERATION AND MAINTENANCE

OPERATION AND MAINTENANCE

OPERATION AND MAINTENANCE