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Autopack 45TLW20VL Technical Manual Download Page 45

4 Maintenance

4-9

4

4.2-3

Initial Setting Level

c

C

C

Set to 5.

Set to C.

Set to 150 for Wrpper & 230 for 
Tunnel.

Set to 30.

Set to PID.

Set to StNd.

Set to OFF.

Set to OFF.

Set to 4

Set to GR-R.

Set to 8.

Set to 0.2.

Set to 0.

Set the value to -169 and wait for 1 sec.
Setting level will jump to 

Advanced

Function Level

 automatically.

Summary of Contents for 45TLW20VL

Page 1: ...Packaging Systems Technical Manual Wrapper Model no 45WLO20FP Shrink Tunnel Model no 45TLW20VL Serial no 1554196 Serial no 1554197...

Page 2: ...ies No Machine No Sign Technical Manual Packaging Systems 1 Introduction 2 Safety precautions 3 Unpacking and Check 4 Maintenance instructions 5 Electrical Components 6 Spare Parts 7 Human Machine Int...

Page 3: ...1 1 1 1 Introduction Immediate danger to life To ensure maximum safety always read the Safety precautions before doing any work on the machine or making any adjustments DANGER...

Page 4: ...1 2 1 Introduction 1 This page intentionally left blank...

Page 5: ...Design modifications 5 Document producer 5 1 2 Machine introduction 6 General Information 6 Shrink Tunnels 6 1 2 1 System Used 6 For Wrapper 6 For Tunnel 7 1 2 2 Machine Design 7 Manufacturer 7 1 3 M...

Page 6: ...1 4 1 Introduction 1 This page intentionally left blank...

Page 7: ...ipment required for service and maintenance The purpose of the electrical components is to provide service technicians and electricians with information on the electrical equipment required for servic...

Page 8: ...e tunnels TMX suitable for most shrink packaging applications Long series heavy duty tunnels THX applicable at all speeds where thicker films and heavy packs are used The machines are of simple modula...

Page 9: ...ay contactor circuit with some electronic control b Conveyor Drive gear motor fixed or variable speed depending on application c Conveyor Belt stainless steel mesh for general purpose tunnels STH uses...

Page 10: ...Machine orientation Definition of direction The below illustrations show the machine from above A indicates the Rear of the machine B indicates the Front of the machine C indicates the Left of the mac...

Page 11: ...2 1 2 2 Safety precautions...

Page 12: ...2 2 2 Safety precautions 2 This page intentionally left blank...

Page 13: ...nd prohibition signs on the machine 8 2 3 Requirements on personnel 9 2 3 1 General 9 3 3 2 Service technician 9 2 3 3 Electrician 9 2 3 4 Machine operator 10 2 3 5 Fork lift driver 10 2 4 Emergency s...

Page 14: ...2 4 2 Safety precautions 2 This page intentionally left blank...

Page 15: ...n operational safety components must be changed immediately 2 1 2 Hazard information Hazard information in this document has the following significance Immediate danger to life Failure to observe this...

Page 16: ...s are marked with the warning sign below Hot surface Failure to observe could result in injuries caused by burning Hot surfaces are marked with the warning sign below The temperature may exceed 60 C P...

Page 17: ...danger Never flush water or any other liquid towards an area with the prohibition sign below Do not touch Failure to observe could result in loss of fingers or other body parts The prohibition sign be...

Page 18: ...2 8 2 Safety precautions 2 2 2 3 Warning and prohibition signs on the machine In the figure below shows the warning and prohibition signs location which are delivered with the machine...

Page 19: ...ck employees who have proper knowledge and training for the service of the Autopack machines technicians employed by the customer Technicians employed by the customer must have the following skills ca...

Page 20: ...a safe and smooth way to assist when assembling Autopack equipment 2 4 Emergency stop In case of danger to people or risk of damage to the machine one of the four Emergency stop buttons must immediat...

Page 21: ...ice work in machine sections not visible from the control panel However for settings of photocells proximity switches frequency converters etc power is needed Stop the machine in the correct way Open...

Page 22: ...area is provided with safety switch This switch is part of the safety system and must under no circumstances be bridged or by passed or otherwise made non operational WARNING Note Also make sure the f...

Page 23: ...After the Main switch has been turned OFF there still can remain high voltage in the electrical cabinet Discharge time approximately five minutes Work inside the electrical cabinet must be performed...

Page 24: ...o not touch hot parts 2 9 Shrink tunnel belt conveyor Risk of personal injury Do not touch the belt while machine is running Failure to observe may result in loss of fingers or other body parts Always...

Page 25: ...iner labels When handling hydraulic oil lubricants and cleaning solutions carefully follow the warnings on the container labels Always use safety equipment according to the instructions on the contain...

Page 26: ...2 16 2 Safety precautions 2 This page intentionally left blank...

Page 27: ...3 1 3 3 Installation...

Page 28: ...3 2 3 Installation 3 This page intentionally left blank...

Page 29: ...k Film 6 3 1 6 Row material limitation 6 3 1 7 Commissioning 6 3 1 8 Shipment by Air 7 3 2 Installation 7 3 2 1 Reassembly procedure 7 3 2 2 Direction of motor 8 3 2 3 Machine communication with upstr...

Page 30: ...3 4 3 Installation 3 This page intentionally left blank...

Page 31: ...ided on the machine The inlet to the ASU is 1 4 P female It is also advisable to provide a 1 4 turn pressure relieving hand valve in line with the air supply just before the unit This is useful during...

Page 32: ...he unit should not be operated prior to commissioning unless a written permission is given by AUTOPACK or its representative company Such action may nullify some points of warranty agreement Item Spec...

Page 33: ...ed mount the conveyor on corresponding holes on the collation table and on top of the support leg At this stage the conveyor should be adjusted so that its top surface is parallel to the top of the ta...

Page 34: ...nside to outside shows the forward direction of rotation Below shows direction of motors looking from the top of the tunnel 3 2 2 Direction of motor Definition of Abbreviations CW Clockwise CCW Counte...

Page 35: ...e unit Take care that cabling and pneumatic pipes is suitably secured and will not touch moving parts For example do not put cabling under conveyor sections where conveyor chain allowed to sag and ext...

Page 36: ...hat the pulleys on the shafts are equidistant on both shafts This distance should be approx 52 mm to centre of the pulley grove Brake Shoe Arm Only optional Should be free to slide sideways so it can...

Page 37: ...4 1 4 4 Maintenance...

Page 38: ...4 2 4 Maintenace 4 This page intentionally left blank...

Page 39: ...9 4 2 4 Advanced function setting level 10 4 2 5 Operation level 11 4 2 6 Adjustment level 11 4 2 7 Protect Level 12 4 3 Inverter 14 4 3 1 Inverter Setting 16 4 4 Air Service Unit 17 4 4 1 Regulator l...

Page 40: ...4 4 4 Maintenace 4 STEP 4 Cceck drive shaft sprocket allignment 25 STEP 5 Check entire belt circuit 25 STEP 6 Adjust tension 26 4 11 Maintenance checks 26 Sleeve wrapper 26 Shrink tunnel 28...

Page 41: ...rations Machines operating at a faster rate should receive 1 drop 40 operations As a starting point for oil feed adjustment turn the adjusting screw clockwise to the end then back off 1 4 to 1 2 turn...

Page 42: ...trol box Months after installation a Check the chain for slacking and remove a few links if required b Check tunnel s belt condition Lubricate top of belt s slides with silicone oil coule of drops per...

Page 43: ...tus of output alarm etc Temperature unit This shows the selectable unit value from controller Display 1 Indicates the running Process Value for temperature Display 2 Indicates the Set point Value for...

Page 44: ...l and mode keys together for at least 1 sec to return to operation level 1 Press the level and mode keys together for at least 3 seconds Dis play indicators will flash for 1 sec and controller enters...

Page 45: ...o 5 Set to C Set to 150 for Wrpper 230 for Tunnel Set to 30 Set to PID Set to StNd Set to OFF Set to OFF Set to 4 Set to GR R Set to 8 Set to 0 2 Set to 0 Set the value to 169 and wait for 1 sec Setti...

Page 46: ...level cse l Set to NC The other values in the advanced function setting level are set to default and should not be changed 4 Press the Level Key for at least 3 sec to return to Operation Level 5 Press...

Page 47: ...essing the mode key button again reach the Alarm limit value AL 1 and set as per the given below For tunnel set to 240 For wrapper set to 160 6 Press the level key for at least 1 sec to go to Adjustme...

Page 48: ...for at least 1 sec to go back to Operation Level 8 Press the level and mode keys together for at least 3 seconds Display indicators will flash for 1 sec and controller enters to Protect Level Set the...

Page 49: ...s restored to normal then a probable cause can be external noise affecting the control system Check for external noise Turn the power OFF then back ON again If the display remains the same the control...

Page 50: ...elected in 2 In this example function code F 00 will appear Even if the function code list for a particular function code group is displayed it is possible to transfer the display to a different funct...

Page 51: ...4 Maintenance 4 15 4 Figure 01 Example of Function Code Data Changing Procedure...

Page 52: ...E34 2 8 1 2 8 1 7 9 0 7 9 0 A n o i t c e t e d t n e r r u c w o L E52 2 2 2 2 e d o m y a l p s i d u n a M d a p y e K F01 1 0 0 0 2 1 t u p n i n o e g a t l o v w o l l a 1 d n a m m o c y c n e...

Page 53: ...vent unauthorized persons adjusting the air pressure It is fixed to the normal air service unit with Lock plate of galvanized steel mounted on the pressure regulating valve using the knurled nut 4 4 2...

Page 54: ...5 Turn the air pressure regulator to the alarm limit 3 bar 6 Turn the setting screw on pressure switch till the yellow alarm is disappeared 7 Manually switch off the safety valve and adjust the air pr...

Page 55: ...4 Maintenance 4 19 4 To move cylinder unlock screw 4...

Page 56: ...4 20 4 Maintenace 4...

Page 57: ...4 Maintenance 4 21 4 4 7 Knife Replacement...

Page 58: ...4 22 4 Maintenace 4 4 8 Welding Bar Heater Assembly Replacement...

Page 59: ...ed backwards on the conveyor Lay the strand down between the two belt edges and check to see that the edge loops are going in the same direction as the belt s edge loops The strand must also be right...

Page 60: ...the wire toward the center and INSERT around the Z bend next to the center space Space D on Diagram D Pull the strand wire through the mesh and STRAIGHTEN it with your pliers Repeat these three moves...

Page 61: ...4 CHECK DRIVE SHAFT SPROCKET ALIGNMENT There should be a 3 16 clearance between all sprockets and or blanks and the Z bends next to them Check alignment of sprocket teeth with a straight edge only nec...

Page 62: ...adjustment Pulleys cones and shaft condition of Brake shoe wear adjustment Shaft end play adj t Film feed if Motor driven Cam for Sensor adjustment Take cover off and check chain lubrication General C...

Page 63: ...and open fully bottom coushion check WBTop and WBBottom Sensors switch operation Safety Clamp bar screws straightness Springs bushes check Condition glueing of knife assy check connections of thermoco...

Page 64: ...or materials or other objects on the bottom of the tunnel check product guides runners and the belt for dislodgement Air flow check if deflectors are in correct position with respect to fan rotation C...

Page 65: ...alves check for leaks check coils are screwed on 9 Electrical system Control Panel Fuses corect value Phase currents correct value Temp control correct Time cycling more than 6 sec setting Check conta...

Page 66: ...4 30 4 Maintenace 4...

Page 67: ...4 Maintenance 4 31 4...

Page 68: ...4 32 4 Maintenace 4...

Page 69: ...4 Maintenance 4 33 4...

Page 70: ...4 34 4 Maintenace 4...

Page 71: ...5 1 5 5 Electrical Components...

Page 72: ...5 2 5 Electrical Components 5 This page intentionally left blank...

Page 73: ...3 1 Electrical Cabinet Wrapper 12 5 3 2 Electrical Cabinet Tunnel 14 5 4 Electrical Component 16 5 4 1 Wrapper 16 Top view 16 Side view 16 Front and Back view 17 Photocells and Proximity switches 17...

Page 74: ...5 4 5 Electrical Components 5 This page intentionally left blank...

Page 75: ...a reference in the diagrams 1 Machine type 2 Drawing number 3 Diagram type 4 Machine area number Drawing Number 9 Electrical diagram 8 Pneumatic diagram Diagram Type S Schematic diagram C Connection...

Page 76: ...ponent T indicates that the component is fitted on the tunnel machine W indicates that the component is fitted on the Wrapper machine C indicates that the component is fitted on the cardboard machine...

Page 77: ...logical order Designation Signification in Electrical Diagram A Assemblies Sub assemblies B Switch F Protective devices G Generators Power supplies H Signalling devices K Relays Contactors M Motors Q...

Page 78: ...ue to lack of space these colours are marked on the circuit and connection diagrams using a number colour code or a letter colour code Colour codes may be follwoed by a dash and a number which indicat...

Page 79: ...5 Electrical Components 5 9 5 5 2 Electrical system description 5 2 1 Safety system...

Page 80: ...5 10 5 Electrical Components 5 This page intentionally left blank...

Page 81: ...5 Electrical Components 5 11 5 This page intentionally left blank...

Page 82: ...yor W9 F320 Table Conveyor WLR WLO W9 F550 Element Welding Bar W9 F960 PLC S2 AM W9 F970 Single phase socket W9 K099 Ready Signal To Upstream W9 K210 Film Drive Bottom Left 45 60 80WX 62 82WX CE W9 K2...

Page 83: ...W9 X950 Main Power Supply Wrapper Unit W9 X951 Control supply W9 X952 Control supply W9 X953 Control supply W9 X954 Control supply W9 X955 Control supply W9 X956 Control supply Splitter optional W9 X9...

Page 84: ...pply THX 208VAC main supply THX T9 F522 Element Shrink Unit Phase C 380VAC main supply THX 208VAC main supply THX T9 F530 Cooling Fan Shrink Unit T9 F910 Control Voltage Input supply 230V AC T9 F911 C...

Page 85: ...ment Shrink Tunnel THX Side Cabinet T9 Q910 Main Switch T9 H910 Main Switch On lamp T9 Q510 Main Fan Shrink Tunnel Left 380VAC main supply 208VAC main supply T9 Q520 Main Fan Shrink Tunnel Right 380VA...

Page 86: ...5 16 5 Electrical Components 5 5 4 Electrical Component 5 4 1 Wrapper Top view Side view...

Page 87: ...B310 Infeed queue Optional W4 B410 Product Sensing W4 B420 Pusher Forward Position W4 B421 Short Stroke Position W4 B422 Pusher Return Position DSBG W4 B424 Table Full Detect Gap Detect W5 B520 Weldin...

Page 88: ...ng RHS Terminals W4 X410 Connection Box Area 4 W5 X510 Connection Box Area 5 W5 X520 Connection Box Area 5 W8 X810 Connection Box Area 8 W9 X921 Connector Plug Power Supply Male W9 X931 Connector Plug...

Page 89: ...cal Components 5 19 5 5 4 2 Tunnel Top view Side view Front Rear Photocells and Proximity switches T5 B511 Thermocouple Shrink Tunnel T7 B710 Tunnel Discharge Queue T6 B611 Tunnel Counter WIM WLO WLR...

Page 90: ...12 Fan Box Tunnel Terminals T5 X530 Connection Box area 5 60TMX T7 X710 Connection Box area 7 T7 X720 Connection Box area 7 Optional T5 X920 Connector Plug Power Supply Female T5 X930 Connector Plug C...

Page 91: ...6 1 6 6 Spare Parts...

Page 92: ...This page intentionally left blank...

Page 93: ...ps for different AUTOPACK system sizes Make sure that you are selecting correct size parts for your machine The systems sizes are 45 60 62 and 80 82 compalsory parts If parts are not marked with the t...

Page 94: ...6 4 Assembly drawing WEL13261 Graphic ID WEL13261 eps Parent Drw WEL13261 dwg KNIFE ASSEMBLY...

Page 95: ...45 2 AKNI13245 00 1 OPTIONAL STOCK COMPLETED KNIFE ASSEMBLY 45W AKNI13260 00 KNIFE ASSEMBLY FOR 60W 62W 1 DKNI122610 00 1 KNIFE FOR MACHINE 60 2 AKNI13260 00 1 OPTIONAL STOCK COMPLETED KNIFE ASSEMBLY...

Page 96: ...6 6 Assembly drawing Graphic ID ANV132610 00 EPS Parent Drw AANV132610 00 SLDASM 060 010 030 040 050 020 ANV13261 ANVIL BAR...

Page 97: ...12D PNP 4mm Om Sensor prox 12mm with connector cable if used ESEI120C4 1O1 1 SensorInd24V12D PNP4mm Om Body ECAB0402C 2O 1 CableConn M12 90Degree 2m Om compalsory parts Rubber pad and Teflon can be su...

Page 98: ...6 8 Assembly drawing SHRINK TUNNEL SPARE PARTS...

Page 99: ...822500 00 2 RUBBER CURTAIN for 82Tx25 DCUR822000 00 2 RUBBER CURTAIN for 80Tx20 DCUR823000 00 2 RUBBER CURTAIN for 80Tx30 DCUR823500 00 2 RUBBER CURTAIN for 80Tx35 DCUR824000 00 2 RUBBER CURTAIN for 8...

Page 100: ...6 10 Assembly drawing Electrical Spear parts Wrapper...

Page 101: ...Blue Ent X956 ETER 3025 6E 15 Terminal Lrge 2 5 5 Blue Ent X960 ETER 3025 6E 3 Terminal Lrge 2 5 5 Blue Ent X961 ETER 3025 6E 3 Terminal Lrge 2 5 5 Blue Ent X962 ETER 3025 6E 3 Terminal Lrge 2 5 5 Blu...

Page 102: ...0 2 ELAM17000 6T 1 Lamp Warning lens blue Te EBUL12015 0C 1 Bulb 24V 0 8W Warm Whit LED H950 3 ELAM17000 4T 1 Lamp Warning lens yellow Te EBUL12015 0C 1 Bulb 24V 0 8W Warm Whit LED H950 4 ELAM17000 2T...

Page 103: ...6 13 Assembly drawing This page intentionally left blank...

Page 104: ...6 14 Assembly drawing Electrical Spear parts Tunnel...

Page 105: ...rload 1NO NC Tele EOVE24 01 0T 1 Contact Overload 1NO NC Tele M910 EFAN221B4 0E 1 Fan unit 220V 4 Dia U610 EINV53715 1F 1 Inverter EMC filter 0 4KW Fuji U610 1 ERIN14180 0B 1 Ferrite Ring for reduce n...

Page 106: ...inned 80Tx ECUR15250 0Y 1 Current indicat 5 50A Yuanxing 45TX EHEA222F0 3I 1 Heater 220V 1500W Finned 45Tx 60TX EHEA222H5 3I 1 Heater 220V 1750W Finned 60Tx 80TX EHEA22320 3I 1 Heater 220V 2000W Finne...

Page 107: ...7 1 7 7 Human Machine Interface...

Page 108: ...7 2 7 HMI operation 7 This page intentionally left blank...

Page 109: ...Optional for SLV Only 5 Stack count Optional for SLV Only 6 Weld Time 6 Pack format 6 7 2 2 Production 6 Batch quantity 7 Batch Identyfication 7 Save data 7 Statistics 7 Maintenance Schedule 7 7 2 3...

Page 110: ...7 4 7 HMI operation 7 This page intentionally left blank...

Page 111: ...p Production Press on Machine Setup to adjust Production Setting and Advance Setting Note Password Level 2 is needed to adjust Advanced Setting 7 2 1 Production Settings 5th Panel Pattern Setting Opti...

Page 112: ...s downwards on the film to make the sealing process It value depends on film thickness Use up and down button to select the weld time and press save button Pack format Number of Push count is accordin...

Page 113: ...h Identyfication Set Product name format and batch number for different product Save data Save data into SD memory card Statistics The statistics screen is showing how many pack per minute and pack ma...

Page 114: ...r Adjust sorting guide movement time to bounce the product Infeed conveyor movement continue When tick in check box the conveyor will stop when the pusher start pushing If no tick in check box the con...

Page 115: ...y push during production This is value which increasing pusher monitor value to control pusher movement forward If real pusher forward time is longer then pusher monitor value pusher alarm is ON 7 3 H...

Page 116: ...ng this indicates a dangerous status such as emergency stop pressed 1 motor overload tripped 2 malfunction of heating system control relays stay too long Off or On 3 This requires an immediate action...

Page 117: ...requires an immediate action from the operator 1 2 3 4 5 6 HMI Screen Machines SSO SLH SLM SLM T SLV SLN SLO SLC SIV SLA SIT CZH CMOS SLH SLM SLM T SLV SLN SLO SLC SIV SLA CZH SLV SIV SLC SSO SLH SLM...

Page 118: ...such as Outfeed queue is full 1 Batch counter full 2 Low Film 3 Splitter jam 4 and Terning 5 1 2 3 4 5 Machines SSO SLH SLM SLM T SLV SLN SLO SLC SIV SLA SIT CZH CMOS SSO SLH SLM SLM T SLV SLN SLO SL...

Page 119: ...8 1 8 8 Diagrams Drawings...

Page 120: ...8 2 8 Diagrams Checks 8 This page intentionally left blank...

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