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MAX PRO 18

©

Operator Manual

Original Printed in English

SECTION 1 - INTRODUC-

SAFETY RULES & PROCEDURES

1

-

1

The machine requires regular, periodic maintenance to ensure reliable service. No maintenance should be per-
formed unless the safety precautions for maintenance are thoroughly understood.

•

Follow all instructions in this manual for safe operation.

•

Follow all company and industry standard safety policies regarding this kind of machinery that may exceed
those listed in this manual.

•

Keep all safety features, guards, interlocks and sensors in good working order.

•

Always ensure that all mechanical motion has stopped and allow any heated components to cool
down before removing any machine parts.

•

Keep the area surrounding the machine free from debris. Spent film/bags should not be allowed to accumu-
late around bagger.

The safety information presented in this manual are guidelines that should be followed by all personnel. Anyone
operating or maintaining the equipment should read and follow all safety information in this manual, without ex-
ception.

All Operators should be familiar with their own Labor Protection Guidelines. Hands, arms, hair and clothing
should not be near any moving or heating parts of the machine. Do not turn the machine ON if any of the ma-
chine’s components have been removed or modified.

EMERGENCY STOP (E

-

STOP) BUTTON

An Emergency Stop (Red) Button is part of HMI/PC Box. The E

-

Stop immediately stops the machine when

pressed bye de

-

energizing power to the PLC outputs, motors, and motor drives.

FIRE PREVENTION

Keep a fire extinguisher near the machine. Keep machine away from any sparks, flames and flammable materi-
als. Unplug the machine before maintaining or cleaning. All electrical components must be in good condition
and clean.

Electrical fires can occur if any wires are scratched, corroded, color

-

faded, lost their insulation or have damaged

wire ends. These should be changed immediately.

Any exposed electrical components should never come into contact with the ground

-

connector and any other

electrically conductive objects such as tools.

It is extremely important to follow all of the safety guidelines and warning detailed inside the Sharp Op-
erator Manual before removing any guards or servicing the machine.

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Summary of Contents for 1174-02

Page 1: ...Original Printed English Copyright 2021 Rev 2 Parts 1 262 246 8815 ext 1571 sharpparts pregis com Service 1 262 246 8815 ext 1572 sharpservice pregis com MAX PRO 18 Operator Manual Model 1174 02 ...

Page 2: ...INTENTIONAL BLANK PAGE ...

Page 3: ...reen 2 13 Bag 2 14 Bag Open Fingers 2 15 Integrated Exit Conveyor 2 16 Load Plate 2 17 Low And High Pressure Air 2 18 Pass Thru 2 19 Pressure Bar 2 20 Printer 2 21 Seal Bar 2 22 Seal Flatteners 2 23 Vacuum 2 24 Support Screen 2 25 SECTION 3 SET UP OPERATION Machine Placement Electrical Precautions 3 1 Grounding Instructions 3 1 Storage 3 1 Power Supply 3 2 Air Supply 3 3 Machine Adjustments Height...

Page 4: ...18 accommodates 18 wide bags with an 8 pass through depth Save job settings and label designs in HMI for easy access Incorporating Zebra thermal printers permits direct printing onto the package for bar codes graphics and alphanumeric fonts Movable printing head sets to precise positions eliminating queuing and reducing material cost and scrap Decrease thermal ribbon usage as much ad 90 with reduc...

Page 5: ...Do not operate the ma chine when tired ill or under the influence of alcohol drugs or medication The instructions and data in this manual are vital to the proper installation and operation of this equipment In order to avoid delays due to faulty installation and operation of the machine please see that these in structions are read by the persons who will install or operate or maintain the machine ...

Page 6: ... this manual without ex ception All Operators should be familiar with their own Labor Protection Guidelines Hands arms hair and clothing should not be near any moving or heating parts of the machine Do not turn the machine ON if any of the ma chine s components have been removed or modified EMERGENCY STOP E STOP BUTTON An Emergency Stop Red Button is part of HMI PC Box The E Stop immediately stops...

Page 7: ... Emergency Stop Button is located on the Control Panel which immediately stops the machine when pressed by de energizing power to the Master Control Relay PLC outputs motor motor drive and air valves OBSTRUCTION SENSING JAW The Sealing Assembly is equipped with Obstruction Sensing Sensors which can detect an obstruction in the Sealing Area If the Jaw Sensors detect and object preventing the Jaw fr...

Page 8: ...Pinch Point This label on the Sharp MAX PRO 18 is placed where there is potential of injury due to pinch points or moving parts Make certain electrical power is discon nected before removing any guards and or panels Risk Of Fire The following label is located in the proximity of a fused circuit Be certain to replace blown fuses ONLY with fuses with the same electrical rating Always dis connect ele...

Page 9: ...lem Phone 1 262 246 8815 ext 1572 E mail sharpservice pregis com SERVICE INFORMATION DECAL The serial number can be found on the Service Infor mation Decal located on the side of the bagger In the above example MAX18 Type of bagger 19L The year and month bagger was built 1174 02 Model Number of bagger XXX The number of bagger SPECIFICATIONS 1 4 BAG WIDTH BAG LENGTH FILM GAUGE MINIMUM 2 5 cm 3 5 8 ...

Page 10: ...MAX PRO 18 Operator Manual Original Printed in English FRONT VIEW Bagger dimensions viewed from front Measurements are in inches MACHINE DIMENSIONS SECTION 1 INTRODUC 1 5 56 5 33 4 34 4 ...

Page 11: ...MAX PRO 18 Operator Manual Original Printed in English TOP VIEW Bagger dimensions viewed from top Measurements are in inches MACHINE DIMENSIONS SECTION 1 INTRODUC 1 6 42 8 74 9 ...

Page 12: ...MAX PRO 18 Operator Manual Original Printed in English SIDE VIEW Bagger dimensions viewed from side Measurements are in inches MACHINE DIMENSIONS SECTION 1 INTRODUC 1 7 38 3 76 4 36 1 ...

Page 13: ... Density SPHD Polypropylene Sharp s Military Specification Film Gamma Patient Sharp s Metalized Barrier Film Electric Static Discharge ESD Modified Atmospheric Packaging MAP Sharp s Non Scratch Film E Z Stat Anti Static Vapor Corrosive Inhibitor VCI Contact Sharp Customer Service at 1 262 246 8815 to order Sharp EZ Bags and for information regarding film and bag specifications THERMAL TRANSFER RIB...

Page 14: ...vice and Manufacturing icons are password protected Pressing any of these three icons will prompt user to type in a password The Operator and Support icons are not password protected NOTE See Supervisor or Manager for correct password for each icon SECURITY SECTION 3 CONTROLS 2 1 ...

Page 15: ...inted in English SCREEN NAVIGATION HOME SCREEN This screen appears at machine start up and by pressing the home button on bottom left corner of screen Pressing any of the 5 large buttons on this screen opens new screen SECTION CONTROLS 2 2 ...

Page 16: ...Green light indicates which job is currently loaded LABEL PRINTER Status Reported status from Zebra Label Printer Pressing About button shows details of the printer Control Pause button pauses printer Only works if you are Service Factory User Darkness Allows user to change darkness of print Only works if you are a Service Factory User Reset Resets internal printer faults e g Printhead errors Labe...

Page 17: ...ed cycle in seconds Average Cycle Time The average cycle time all cycles in seconds Reset Average Cycle Time Reset or clears the average cycle time SEAL BAR TEMPERATURE Current The current temperature of Seal Bar Required The temperature of Seal Bar per settings in loaded job MACHINE COUNTERS Informational display of counters and cycles of bagger OPERATOR BAGS Operator Resettable bag counter ...

Page 18: ... Button from the Home Screen opens the Job Setup Screen This screen allows a Us er to configure Bag Dimensions and Feed Speed Bag Opening Package Eject Pressure Bar and Seal Bar Auxiliary Input output and Printer Access to this screen is password protected SCREEN NAVIGATION SECTION 2 CONTROLS 2 5 ...

Page 19: ... inches less than the measured overall bag length Skirt Length The distance from the bottom of the bag to the start of the seal Width The width of the loaded bag Thickness The thickness of bag material BAG FEED SPEED Forward Adjusts the forward web speed in inches per second Reverse Adjusts the reverse web speed in inches per second BAG OPENING Bag Opening Retry Count Display the number of attempt...

Page 20: ...thru will change move once job is loaded LOW PRESSURE AIR Press box in middle to set timeout for LPA at end of cycle to hold bag open Always OFF Always OFF Always ON Always ON HIGH PRESSURE AIR HP Air Dwell Sets the length of time in seconds the High Pressure Air blasts VACUUM Vacuum Dwell Sets the length of time in seconds that Vacuum creates suction SCREEN NAVIGATION SECTION 2 CONTROLS 2 7 ...

Page 21: ... drop before feeding new bag out LPA LPA Bag Eject Assist Toggle switch turns LPA ON or OFF to assist the ejection of sealed bag INTEGRATED EXIT CONVEYOR Runtime Timeout for Integrated Exit Conveyor starts when package starts to fall LOAD PLATE Load Plate Dwell Timeout for load plate in discharge position Load Plate Delay Starts when bag starts to fall SCREEN NAVIGATION SECTION 2 CONTROLS 2 8 ...

Page 22: ... closing the Pressure Bar SEAL BAR Dwell The amount of time the heated seal bar will remain in contact with the film High quality seals are accomplished through proper seal time settings These settings will vary with the film gauge and materi al Temperature Sets the desired temperature of seal bar Separate Before Seal Toggle switch that turns ON OFF a feature that prior to sealing the bag will rev...

Page 23: ...Warning appears when this is active OUTPUT 1 Not Configured No configuration Printer Data Ready Output active when Printer is ready for a new label Waiting For Printer Machine is cycling and film is backed up and ready to print but printer needs label Cycle Complete Cycle done Bag Made Bag is dropping Bag Made Label Required Bag is dropping AND printer needs a label Bags Low Bags low sensor is act...

Page 24: ...guration Printer Data Ready Output active when Printer is ready for a new label Waiting For Printer Machine is cycling and film is backed up and ready to print but printer needs label Cycle Complete Cycle done Bag Made Bag is dropping Bag Made Label Required Bag is dropping AND printer needs a label Bags Low Bags low sensor is active SCREEN NAVIGATION SECTION 2 CONTROLS 2 11 ...

Page 25: ...ic setting determines the distance the web will feed during the print cycle This should be set to smallest value that will produce the desired label This setting is approximately of inch longer than the length of the label Offset This numeric setting determines the starting position of the printed label This can be used to adjust the label position on the bag It is adjustable from 0 to 10 00 Clear...

Page 26: ...ll open the Appli cations Settings page Any changes made to this screen requires operator to press Load Job or Save Load button Application This allows a User to select HMI Language and to activate Demo Mode Demo Mode When demo mode is active the controller automatically sends a test label to the printer on every cycle SCREEN NAVIGATION SECTION 2 CONTROLS 2 13 ...

Page 27: ...ers Integrated Exit Conveyor Load Plate Low Pressure Air High Pressure Air Pass Thru Pressure Bar Printer Seal Bar Seal Flatteners and Vacuum Access to this screen is password pro tected HMI COMPUTER Minimize HMI Program This button will minimize the HMI program but leaves Operating System open Close HMI Program This button closes the HMI program Shutdown Computer Closes the HMI program and shuts ...

Page 28: ...Reverse button will reverse the web as long as button is pressed Forward Pressing Forward button will advance the web as long as button is pressed BAGS MADE Total Displays the total number of completed bags since last reset BAGS REJECTED Total The total number of bags that have been rejected since last reset Reset Counters Pressing Reset will clear the Total Bags Made or Bags Rejected totals 2 15 ...

Page 29: ...down Release Fingers will Rotate up to release the bag CYCLES Total The total number of cycle the Bag Open Fingers have completed since last reset OPEN RETRIES Total The total number of times the Bag Open Fingers have attempted to open fed bag Reset Counters Pressing Reset will clear the Cycles or Open Retries SCREEN NAVIGATION SECTION 2 CONTROLS 2 16 ...

Page 30: ...to run exit conveyor until released This will change the Dwell Apply To Settings Time that jog was pressed can be set to job dwell setting Job saves automatically but is not loaded PULSE DWELL Current Press to run conveyor at job setting Pulse Sec Press to run conveyor at job setting Setting Time for conveyor to run when Pulse Sec is pushed Changing this setting will save to job but not load the j...

Page 31: ... To Discharge Moves the Load Plate to the Discharge position To Load Moves the Load Plate to the Load Position CYCLES Total Displays the total number of complete Load Plate cycles since last reset Reset Counter Reset the Cycle Total Counter SCREEN NAVIGATION SECTION 2 CONTROLS 2 18 ...

Page 32: ...etting in loaded job Current The actual setting of Low Pressure Air blast Pulse Sec Runs Low Pressure Air for job setting dwell HIGH PRESSURE AIR Activate Turn on the High Pressure Air as long as button is pushed Current The amount of time the High Pressure Air will be ON according to setting in loaded job Setting The actual setting of High Pressure Air blast Pulse Sec Runs High Pressure Air for j...

Page 33: ...ches Face Plate Jog OUT Moves Jaw outward as long as button is pushed or until it reaches end of travel MANUAL POSITION Current The actual width of Jaw Move To In Moves Jaw to width set in job settings Setting Active job setting for Pass thru POSITION CHANGES Total Displays the total number of changes to Pass thru since last reset Reset Counters SCREEN NAVIGATION SECTION 2 CONTROLS 2 20 ...

Page 34: ...t or close the Pressure Bar Pressure Bar will remained closed until Move OUT is pushed Move OUT Pressing this button will extend or open the Pressure Bar CYCLES Total Total number of Cycles the Pressure Jaw has completed since last reset Reset Counter Resets the Total Cycles Counter SCREEN NAVIGATION SECTION 2 CONTROLS 2 21 ...

Page 35: ... of labels loaded into printer Clear Queue Clears the Queue of loaded labels Send Test Sends one Test Label to printer for a test print Send File Opens a Select Label File Dialog Box User can navigate to stored labels on computer to load into Job CONFIGURATION Expert use only Darkness Allows user to change darkness setting Settings Exposes all available printer settings expert use only Console Exp...

Page 36: ...e IN button is pressed CYCLE Current Displays the length of time Seal Bar is active Pulse Sec Cycles the Seal Bar There must be a time set in job settings or Current or Seal Bar will not move Setting Displays the Job Setting for temperature SEAL BAR CYCLES Total Number of completed Seal Bar Cycles since last reset Reset Counter Resets the Seal Bar Cycles Counter SCREEN NAVIGATION SECTION 2 CONTROL...

Page 37: ...tton is pressed or until fingers reach center Jog OUT Moves fingers OUT as long as button is pressed or until fingers are completely out MANUAL POSITION Current This setting determines the IN setting for the fingers Move To In This button moves the fingers to the Current Setting If Current Setting is zero fingers will move to center of sealing area CYCLES Totals The number of completed Seal Flatte...

Page 38: ...on Vacuum Vacuum will stay on until button is pressed again DWELL Current The actual setting of the Vacuum ON Pulse Sec Pressing the button will turn Vacuum ON for length of Dwell Setting Setting The actual length of Vacuum on when button is pushed SCREEN NAVIGATION SECTION 2 CONTROLS 2 25 ...

Page 39: ...vides the contact information for Sharp Service and Sharp Parts Also provides Sharp Packaging Systems mailing address SOFTWARE VERSIONS Displays current Software Upgrade From File Allows for mapping to saved HMI program file used to upgrade program 2 26 SCREEN NAVIGATION SECTION 2 CONTROLS ...

Page 40: ...aving an equipment grounding conductor for a 3 prong grounding plug The plug must be connected into an outlet that is properly installed and grounded in the accordance with all local codes and ordinances Do not modify the plug provided with the machine If your electrical supply does not meet the above specifications or if you are unsure your building has an effective ground have a qualified electr...

Page 41: ...OFF position 2 Plug Male End of Power Cord into properly grounded wall outlet or electrical drop 3 Insert Female End of Power Cord into the Power Entry Module on back of Electrical Box The box is in the Frame Assembly 4 Turn the switch on the Power Entry Module to ON position 5 Plug the Male End of second Power Cord into a properly grounded wall outlet or electrical drop 6 Insert the Female end in...

Page 42: ...ricated air on the machine Damage to valves and cylinders will occur 1 Connect Air Hose to Regulator 2 Unlock Cap on Regulator 3 Adjust to 80 PSI 4 Lock Cap on Regulator HEIGHT ADJUSTMENT Machine height can be adjusted to allow manual load ing at a convenient height 1 Release the Handle on the Adjustment Wheel 2 Turn the handle on the side of the bagger to ad just the height up or down to the desi...

Page 43: ...p Screws LOAD SHELF The Load Shelf can be moved up or down to accom modate different sized bags 1 Loosen the Locking Handles on back of Load Plate 2 Move Load Shelf to desired location 3 Tighten the Locking Handles LOAD PLATE The Load Plate can also be moved up or down to ac commodate longer bags 1 Loosen the Load Shelf Locking Handles 2 Remove the Ring Pins move plate to desired location and repl...

Page 44: ...u when standing behind box 1 Raise the Cradle Printhead Cradle and Unwind Cradle by rotating the Latches and open the Cra dles 2 While standing at the right side of the machine feed film over Drag Tube of Box Tray 3 Then under over Unwind Drag Tubes then under Idler Roller finally over the Unwind Drive Roller Close Unwind Cradle Latch Position Weight Straps over Box Tray Drag Tube 3 5 Use extreme ...

Page 45: ...ted in English 4 Pull the film Under the Printer Carriage until edge drapes over the Platen and Drive Rollers and down past the Front Finger Plate 5 Lower and lock the Drive Roller Cradle Latch LOADING BAG FILM 3 6 SECTION 3 SET UP OPERATION ...

Page 46: ...oard tube into carriage let hang loose 4 Place a new roll of ribbon onto the Ribbon Unwind hub 5 Thread the ribbon under Ribbon Roller Sleeve under Return Ribbon Shaft around Printhead then up and over Ribbon Return Shaft to Ribbon Rewind Hub 6 Place empty cardboard roll onto Ribbon Rewind Hub 7 Turn knob on Take Up Spool counter clockwise to ensure ribbon is tight 8 Close the Printhead Cradle Cov...

Page 47: ...e bagger NOTE The machine will display several faults and warnings when HMI program and Power Button have been pressed 7 Press the Enable Bagger Button This will estab lish communication and clear faults of Home Pres sure Bar Seal Flattener and Bag Feed 8 The Seal Bar Not At Temperature warning will remain until Seal Bar reaches loaded job tempera ture setting 9 Press the Operator button to open O...

Page 48: ...chine surfaces Particles of steel wool may break off and cause rusting or contaminate lubricated surfaces DO NOT allow wrenches fittings or other metallic objects to lie on machine surfaces during opera tion DO NOT use chlorine ammonia alkalis acids or cleaning solutions that will damage metallic ma chine surfaces cause corrosion or contaminate containers SEVERE DUTY APPLICATIONS Some applications...

Page 49: ... Inspect the Unwind Pinch Roller Clean as needed See Unwind Pinch Roller Cleaning Procedure page 2 10 Verify the Pinch Roller spins freely when latch is opened Inspect the Teflon Tape that covers the Pres sure Bar Anvil Rubber and replace if worn or damaged MONTHLY CLEANING MAINTENANCE All of Weekly maintenance Inspect the Air Filter for debris and replace as necessary Inspect all external wiring ...

Page 50: ...vents or cleaning solutions on the sensing por tions of eye PRINTHEAD 1 Turn the Printer Control Box OFF 2 Open the Printer Carriage by releasing the Draw Latch on side of Printer Carriage 3 Clean the Printhead thoroughly using a soft lint free cloth and 99 7 isopropyl alcohol 4 Allow the solvent to evaporate 5 Return power Bag Edge Present Sensor SECTION 3 SET UP OPERATION ...

Page 51: ...eat until roller is clean 5 Repeat for Platen Roller 6 When rollers are clean close the Cradle Latch 7 Return power and air to bagger PINCH ROLLER After Cleaning the Drive Roller clean the Pinch Roller in the Cradle Latch Assembly 1 Open the Cradle Latch 2 Pinch Roller is behind Front Air Knife Cover but can be accessed from below cover when Cradle is opened 3 Moisten a lint free cloth with Isopro...

Page 52: ... when finished 1 Power up the machine according and apply air to regulator 2 Release the E Stop Button and press the Green Power Button 3 Allow Seal Bar to reach set temperature 4 Access the Service Screen from the Main Screen The Service Screen is passcode protect ed See Supervisor to gain access 5 Press the Extend Seal Bar Button to change the state of the Seal Bar 6 NEVER use any metallic utens...

Page 53: ...loth with Isopropyl Alcohol and rub back and forth along Unwind Drive Roller 4 Rotate roller and repeat until roller is clean PINCH ROLLER After Cleaning the Unwind Drive Roller clean the Un wind Pinch Roller in the Latch Assembly 1 Open the Cradle Latch 2 Moisten a lint free cloth with Isopropyl Alcohol and rub back and forth on the Pinch Roller 3 Rotate roller and repeat until roller is clean 4 ...

Page 54: ...t the Green Pow er Button has not been pressed Release the E Stop press the Green Power Button and the Bag ger Enabled button E Stop tripped or Power not Re set E Stop Button was pressed or E Stop is released but the Green Pow er Button has not been pressed Release the E Stop press the Green Power Button and the Bag ger Enabled button Seal Bar Thermal Runaway Not Heating Seal Bar not heating up at...

Page 55: ... Controller and I O master have been interrupt ed Verify cables are connected and tightened properly Communication Fail I O Master to I O Node Communications between I O Mas ter and expected I O node have been interrupted Verify cables are connected and tightened properly Master I O Communication Fail ure Controller Disconnected The controller is disconnected Connect the controller Palm Button Con...

Page 56: ...n filled and sealed in Filler Mode No action is required Bag Level Low Bag are getting low in box Prepare to replace bags soon Demo Mode Is Active Bagger s demo mode is active Disable demo mode in Set tings Demo to turn off this warning Factory Test Mode Is Active Bagger is running in Test Mode Turn Factory Test OFF in Factory Setup Factory Test Machine Not Tested Bagger life cycle count is not ov...

Page 57: ...fied Product Install a genuine Zebra print head Head Element Out A printhead element is no longer working If the location of the failed ele ment affects printing replace the printhead Replace Printhead The printhead is nearing the end of its life and should be replaced Replace the printhead Head Maintenance Needed The printhead needs to be cleaned Clean the printhead See Clean ing the Printhead on...

Page 58: ...e print line is not at an optimal position for your media Adjust the print line for thick media Print Consistently Too Light or Too Dark Issue Possible Cause Possible Solution s Printing is too light or too dark over the entire label The Printer is set at an incorrect darkness level For optimal print quality set the darkness to the lowest possible setting for your application Incorrect printhead p...

Page 59: ...ble Cause Possible Solution s Fine angular gray lines on blank labels Wrinkled ribbon Verify the ribbon is loaded properly smooth out ribbon Missing Print Issue Possible Cause Possible Solution s Long tracks of missing print on several labels Print element damaged Call for service Wrinkled ribbon Verify the ribbon is loaded properly smooth out ribbon ...

Page 60: ...chine which is returned transportation prepaid to Sharp s authorized service center within the warranty period The warranty starts on the date the machine is delivered to the original Buyer and expires one 1 year for parts and ninety 90 days for labor after that date Buyer at Sharp s request shall provide documents establishing the delivery date Exclusions This war ranty shall not apply to a any m...

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