Repak RE20 User Manual Download

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Repak

Phileas Foggstraat 18, 7821 AK EMMEN, The Netherlands.
Phone +31 (0)591 668010, Fax +31 (0)591 676076, www.repak.nl

User Manual

for the start-up and operation of the

Thermoforming Packaging Machine

part 1: operator

Summary of Contents for RE20

Page 1: ...k Phileas Foggstraat 18 7821 AK EMMEN The Netherlands Phone 31 0 591 668010 Fax 31 0 591 676076 www repak nl User Manual for the start up and operation of the Thermoforming Packaging Machine part 1 operator ...

Page 2: ...achine manufacturer Service department address Language English Repak B V Version 2 165b Publication date Jan 2019 Repak B V Phileas Foggstraat 18 7821 AK Emmen Tel 0031 0 591 668 010 Fax 0031 0 591 676 076 No part of this publication may be copied or given to third parties without the express permission of Repak ...

Page 3: ...ms chapter 2 11 and the spare parts list chapter 12 Part one contains all the information the operator requires to start the machine up and run it These are activities that do not require tools of any kind The technical part describes the electrical and pneumatic diagrams and the third part contains the parts lists and construction drawings relative to the machine The standards that the machine me...

Page 4: ...EN 614 1 2006 A1 2009 Part 2 interaction between the design of machines and work tasks NEN EN 614 2 2000 A1 2008 Safety of machines General requirements for the design and the protection of screens fixed and movable NEN EN 953 1998 A1 2009 Safety of machines Parts of control systems with a safety function Part 1 general design principles NEN EN 954 1 1997 Safety of machines Parts of control system...

Page 5: ...tters 49 3 12 Discharge conveyor belt 53 3 13 Control cabinet 54 3 14 Drive gear 55 3 15 Film edge trim removal 56 4 Control panel 59 4 1 How the touch screen works 59 4 2 Machine operating menus 61 4 3 Operator menu 65 4 4 Main menu 75 4 5 Access code 101 5 Operating the machine 103 5 1 Preventive measures and safety instructions 103 5 2 Turning on the machine 106 5 3 Fitting the rolls of film 11...

Page 6: ... die Here a shape is produced in the film by a combination of heat and pressure In the next part of the machine the loading area the shaped film pockets are filled with the product to be packaged In the next area the sealing die the top film is applied to the top of the pack and sealed to it During the sealing process the pack can if so desired be sealed under vacuum or filled with gas Subsequentl...

Page 7: ...trol cabinet 6 top film unwind unit 7 cross cutting unit 8 longitudinal cutting unit 9 conveyor belt 10 drive system 11 lifting system 12 vacuum pump In addition to the parts shown here the machine can also be fitted with various kinds of peripheral equipment This includes labeling equipment filling machines printing equipment etc Please refer to the relevant manuals for the operation of such equi...

Page 8: ...creen see Figure 1 2 There is a complete description of the touch screen in the chapter entitled Control Panel In addition to the control panel the machine also has a number of other control mechanisms These are exclusively for the use of the technical department or the supplier and they are not dealt with in this part of the manual Touch screen Emergency button start button stop button Figure 1 2...

Page 9: ... 50 60Hz 3 230V 60HZ USA CA Phase 3Ph N PE 3 Ph PE USA CA Power 15 kW Nominal current 35 A 35 A fuses Noise level 70 dB Minimum Maximum Water 0 5 bar 3 bar 60 liters hr 20 Gallons hour Pressed air dry 6 bar 7 bar 90PSI 35 CFM Gas 4 bar 6 bar Relative humidity 70 System characteristics Dimensions l x w x h RE20 4000 5000 6000 x 1050 x 1950 mm Weight ca 2200 2600 kg incl Vacuum pump Film unwind unit...

Page 10: ...n achieve an average of 12 cycles per minute The duration of a program is affected by The dimensions of the packaging length width and height The type of film used The safety pauses between the stages The final vacuum required in the packaging Etc For a machine to work optimally the program settings must be fine tuned by trained staff Influences from the immediate environment The principal conditi...

Page 11: ...rvice life the machine should be dismantled properly and disposed of in accordance with national regulations Ensure the following while disposing of components of the machine Send metal parts for recycling Send plastic parts for recycling Send electrical and electronic components for hazardous waste disposal Recommendation Contact a company specialised in disposal ...

Page 12: ...al safety instructions 13 2 2 Intended use and use not recommended 15 2 3 Meaning of the symbols 16 2 4 Safety systems 19 2 4 1 Protection covers 20 2 4 2 Metal cover plates 21 2 4 3 Side plates 21 2 4 4 Emergency switch 22 2 4 5 Pressure switches 22 2 5 Transportation 23 ...

Page 13: ...ng on the machine turn off the power and the air supply unless otherwise indicated Shutting off the air supply immobilizes the moving parts and the blades Repairs are to be carried out exclusively by Repak or by an expert trained by Repak It is not allowed to make adjustments to the machine without written approval from Repak B V Use the built in safety systems and maintain them Making changes to ...

Page 14: ...ipment The cables connecting the control cabinet and the external equipment should be so arranged that nobody can trip over them Observe the safety guidelines contained in the manuals for the supplementary equipment Keep your body parts well away from rotating components such as the blades and film unwind units Do not wear loose clothing Do not wear chains Do not have your hair long and loose Neve...

Page 15: ...vers side plates roller conveyor and safety covers Never use the machine without a support tray Do not wear any rings on the hands nor a chain or wristwatch while the machine is running Never interfere with the machine s moving parts Use ear protection when the machine is running Working with the machine is only permitted after user instructions have been received from Repak or one of its agencies...

Page 16: ...nd the person using the machine Figure 2 3 indicates the various danger zones and warnings Figure 2 3 Danger Zones No Machine part Dangers 1 Film infeed 2 Forming station 3 Sealing station 4 Cross cutter 5 Longitudinal cutter 6 Control cabinet 7 Main motor 8 Lifting equipment 9 Vacuum pump 10 Drive chains 11 Conveyor belt 10 00 00 00 2 3 6 4 5 11 7 9 8 8 1 ...

Page 17: ...ain motor 7 longitudinal cutter motor 5 and vacuum pump 9 Meaning DANGEROUS Rotating parts Danger Among other things rotating parts can crush limbs Recommendation Approach rotating parts only when the machine is turned off Do not wear loose clothing Do not wear chains Do not have your hair long and loose Do not interfere with the lifting equipment Can be found in forming station 2 sealing station ...

Page 18: ... on the outside During maintenance work always place the blade shaft in the protective cover supplied Can be found in longitudinal cutter 4 longitudinal cutter 5 sealing station 3 Meaning DANGEROUS Hot surface Danger Hot components can cause serious burns Recommendation After the main switch has been turned off hot components need a considerable amount of time to cool down approximately 1 hour Wea...

Page 19: ...of the safety system Figure 2 4 Safety systems Removable safety covers 1 sealing station 2 forming station outfeed 3 forming station infeed 4 longitudinal cutter and cross cutter 5 space between chain track and machine frame Fixed safety covers 6 end parts of conveyor belt 7 support tray 8 forming station infeed 9 film infeed 10 underside of conveyor belt 11 drive belt 12 top film infeed 13 chain ...

Page 20: ...start the machine the plate must be replaced and the start up procedure repeated see paragraph 5 2 5 2 The plates on the machine are not interchangeable so always put them back in the correct place If the plates are placed in the wrong place an error message is displayed in the control panel status line In order to guarantee that the covers work properly both they and the surfaces on which they re...

Page 21: ...fitted with a clip that fits around the shaft of the infeed roller These plates have to be removed in a horizontal direction The cover plates at the main drive are not removable 2 4 3 Side plates The sides of the machine are covered by a number of side plates These thin metal plates are fitted on the underside with a number of clips for fixing them to the frame The upper side of the plate fits int...

Page 22: ...nt of the control panel and can be recognized by its red color and yellow edge see Figure 2 8 When the emergency switch is pressed the machine stops its cycle immediately pressure drops in the equipment Note the cylinders of the lifting systems and the film punch keep their position when the emergency switch is activated The technical department should be called in to solve any technical problems ...

Page 23: ...n of your machine Due to the modular construction the transport methods can be different for each machine IMPORTANT Wrong handling of the machine during relocation could do serious damage to the machine and endanger present personnel Repak BV cannot be held responsible for accidents resulting from a failure to contact the supplier ...

Page 24: ...g film brake 41 3 7 4 1 Non stretchable packaging material 41 3 7 4 2 Moderate stretchable packaging material 41 3 7 4 3 Good stretchable packaging material 41 3 7 4 4 Highly stretchable packaging material 41 3 8 Description of sealing station 42 3 9 Cross cuttings 43 3 9 1 Flexible film cutter 43 3 9 1 1 Method of operation 44 3 9 1 2 Knife forms 44 3 9 2 Film puncher 46 3 9 2 1 Method of operati...

Page 25: ...25 ...

Page 26: ...d between the top part of the mould and the bottom part The upper plate has a temperature of between 80 120 C and 176 248 F and ensures that the film can be shaped At that point compressed air forces the film into the forming cavities in the bottom part The bottom part is cooled and the packaging shape releases as the lifting system lowers to its original position The film is now transported one s...

Page 27: ...rts are made of stainless steel aluminum and plastic HMPE 500 These materials were chosen to keep corrosion to a minimum This is to the advantage of hygiene and the machine s lifespan The previous paragraph described the entire process in simplified form All the machine parts described there will be further described in the paragraphs below The illustrations can vary depending on the machine s con...

Page 28: ...they close again at point B and clamp the film on both sides An infeed roller is positioned between both chain wheels to guide the film properly into the chain clips 3 3 1 Film tracking adjustment Film tracking can be adjusted with the knob at the left side of the tracking frame with weight plate WP 400 and CK 400 when turning this one turn clockwise the film roll will be moved for 2 mm to the rig...

Page 29: ... film tension during unwinding is created by the cover that rests on the film roll which also prevents the fiilm unwinding by itself The weight plate is mounted on two slots to enable changing of the weight on the film roll By moving up the weight plate the weight on the film roll will be decreased By pulling down the weight plate in its slots the weight on the film roll will be increased The film...

Page 30: ...m is pulled forward during unwinding the brake will be released to unroll the film The tension arm is connected to a spring which brings the arm back to its start position at the end of the film advance Each film advance of the machine will pull the tension arm forward This will be checked by a sensor which is placed just behind the tension arm in the blue brake box If the arm stays at its positio...

Page 31: ...eels with a diameter up to 1200mm This device will be delivered with two exchangeable carriages on each a film reel can be placed so a reel change can be carried out very quickly By using large diameter reels the machine can run for longer periods before running out of film The detailed documentation and functioning of the Jumbo unwinder is placed in chapter 12 of the machine manual Figure 3 6 Jum...

Page 32: ...rocess can be done in a variety of ways The basic principle is as follows Before the process starts the forming device closes The film is pressed against a heating plate in the top part by compressed air The hot and weak film is pressed and or sucked depending on the machine s configuration into the cavity or cavities in the bottom part The film cools and stiffens in the forming die bottom part Th...

Page 33: ...s closed The forming die top part heats the film until it is weak enough to be formed Then the forming station opens and the film is transported one stroke length forward Here one stroke length is approximately half the length of the forming station The forming station then closes again and the heated film is now in the second part of the device Compressed air with or without vacuum support brings...

Page 34: ...re less Warning Caution crushing danger 3 5 1 Product support bars The product support bars are situated in the loading area and outfeed extension see figure 3 9 These aluminum profiles prevent the filled package from sagging too much The number of support bars are dependent on the index of the forming tools The bars can be placed and removed easily by lifting up the infeed side and then pulling i...

Page 35: ...s is achieved with shorter product support bars see figure 3 9 pos 3 The crosscutting is situated on the outfeed extension Support is needed especially before and after the cross cutting device see figure 3 9 pos 2 At the longitudinal cutter no 1 the product support bars have extra functions providing protection from the blades and positioning the packages in accordance with the knives ...

Page 36: ... station will stay in their final form making it easier to fill the packages with products After the forming station lifting system lowers the confirmation station will stop its cycle the vacuum valve will close the ventilation valve will open and the box goes to its lower position 3 5 3 Loading mask The loading section can also be provided with a loading mask see fig 3 11 This mask avoids moistur...

Page 37: ...37 Figure 3 11 Loading mask Loading mask Lifting pin Lifting system ...

Page 38: ...nto the bottom film Its functioning is the same as described in paragraph 3 3 2 3 7 Photocell and film brake When a printed top film is used a photocell and a film brake see Figure 3 13 ensure that the print is in the correct position on the package The photocell detects the position of print marks and the film brake corrects the distance with reference to the bottom film Figure 3 13 Photocell Pho...

Page 39: ... max roll diameter suitable drive for film transport photocell with film brake 3 7 2 Explanations of notions Repeat print Print design with repeating distance between each print Repeat length a Adjusted distance between two consecutive prints The repeat length a is identical to the stroke length in the format drawing Tolerance repeat Relative total deviation Δ U and absolute individual deviation l...

Page 40: ...rawing In case of transparent film the print marks must be placed at the outside non sealing side of the film The print marks on top web should be detectable by the photocell on the machine 3 7 3 3 Print mark integrated in print design Important There must be a minimum of 20 mm distance from print in the advance direction 3 7 3 4 Adhesive tape seam The tape seam may not activate the photocell So u...

Page 41: ...e polyester bi axial stretched polyamide mono and bi axial stretched polypropylene bi axial stretched etc relative total deviation Δ U 0 1 up to 0 5 1 up to 5 mm on 1 000 mm Absolute individual deviation max 1 5 mm 3 7 4 3 Good stretchable packaging material for instance PA PE non stretching etc relative total deviation Δ U 0 2 up to 0 7 2 up to 7 mm on 1 000 mm Absolute individual deviation max 2...

Page 42: ... inside the packages to an adjustable value Then depending on the type of packaging a preservative gas is blown into the package and the package is sealed To achieve this a heating plate is pressed down on to the package s and the high temperature melts both top and bottom films together Also it is possible to produce vacuum packages then the sealing process will instead start directly after the v...

Page 43: ...oss cutting involves separating the sealed packages from one another in a crosswise direction The cross cutter works according to the principle of a guillotine The guillotine is mounted in the discharge end extension see Figure 3 15 and is movable in the machine length to position the guillotine exactly in between two packages The guillotine cutter consists of A Base unit B Top half with knife C C...

Page 44: ... down to cut After the cutting operation the compressed air supply is cut off and the springs push the blade holder back The cutting support returns to its original position see fig 3 16 3 9 1 2 Knife forms Various knife forms are available for different applications Knife blade straight cut This knife is the standard knife 1 1 Figure 3 16 Cross cut Guillotine Cutting support Springs Membrane Knif...

Page 45: ...aid to the packages Important 4 It is only possible to install knives of the same thickness into the knife assembly If you for example would like to change a straight toothed knife against a zigzag knife you have to change the complete top half assembly and the counter pressure plate ...

Page 46: ...h cutting tool change there is no need to readjust the punch every time 3 9 2 1 Method of operation The cutting table with pressure bar which runs up and down in the punch bottom is pushed up against the interchangeable blade holder in the punch top A rugged lever system which locks automatically when the cutting table reaches its highest point guarantees high and uniform cutting pressure The top ...

Page 47: ...r level till top part D just touches the pressure bar C 5 Fasten nuts B to keep top part on its place 6 Run machine till film is in cutting section 7 Fine adjustment by turning nuts A 1 12 turn to a lower level till cutting is perfect over the whole width Control the cut after each change Important After change always check all nuts and bolts Adjust nuts A only as deep as necessary so when pressur...

Page 48: ... connected to the knife plate goes down to cut the packages out of the film The pressure and the air speed to cylinder A is adjustable to a level just enough to strain the film a little during cutting The knives goes smoothly through the film and the air cylinder A brings the packages by product pushers through the counter plate to the integrated conveyor When the knife plate reaches the sensor fo...

Page 49: ...electric motor A plate above the film and support bars below the film holds the film in the correct position during the cutting process The film edge trims can be removed by a film trim suction unit or the film trim rewind system When maintaining or cleaning the longitudinal cutter the following instructions should be followed Always store the spare shaft with blades in the wooden box delivered wi...

Page 50: ...ife by a perforation knife 3 11 2 1 Method of Operation The cutting roller is turned synchronously with the film advance on the packaging machine by a gear which is driven by the drive of the transport chain The blades in the squeezing knife holders are pressed against the hardened cutting roller by pneumatic cylinder This kind of cutting simply presses into the film material and the remainder of ...

Page 51: ...s The packaging dept is limited at 120mm perforation cutting is not possible 3 11 3 2 Method of Operation Two circular knives working in opposite directions which overlap at their circumference are mounted above and below the film level see Figure 3 25 They cut the film at their contact points in the manner of a pair of scissors A strip of film about 4 mm wide is cut out between the packages In co...

Page 52: ... film level They cut the film at their contact points in the manner of a pair of scissors see Figure 3 26 3 27 There is a straight cut between the packages In combination with the rigid film puncher this cutter produces a smooth transition to the rounded corners 3 11 4 3 How to exchange the cutting units Wear chain mess gloves when changing the roller shear knife sets The method can be described i...

Page 53: ...conveyor is adjustable for the height of the packages The conveyor belt should not be adjusted while the machine is running At the end of the conveyor the products have to be removed from the belt by another conveyor belt a person or a robot Take care that body parts or hair do not become trapped between the belt and the guidance mechanism Figure 3 29 Discharge conveyor ...

Page 54: ...s connections for compressed air electricity water and gas see Figure 3 31 Make sure that the cables connected to the control cabinet are so arranged that no one can trip over them The control cabinet has a control panel that is discussed in Chapter 4 The entire machine can be run from this panel Figure 3 30 Control cabinet Figure 3 31 Connections A B D C A Gas connection B Water drain C Pressed a...

Page 55: ...aft This causes the chains always to run at the same speed There are two chain tensors in the drive gear If the chain tension is too high or too low it can be easily adjusted with the adjusters This procedure can be found in Part 2 of the Manual Figure 3 32 Drive gear Main shaft Chain wheel Chain adjusters Electric motor ...

Page 56: ...nit The film edge trim will be removed by vacuum through hoses which are connected to a suction unit The film trim will be collected in the suction unit into a stainless steel drum which is removeable for emptying The film edge trim adaptors are mounted at the discharge end extension of the machine and are adjustable to optimise its functioning The vacuum hoses are connected at one end into the ad...

Page 57: ... the photoelectric sensor is deactivated and stops the motor In this way the tension arm keeps constant tension on the strips The wound up trim is easy to dispose of just take it off the removable reel disks 3 15 2 2 Routing of edge trim First run machine until the edge trim is out of the machine by ca 2 metres then turn off each motor switch to stop the motors Route the strip by following the arr...

Page 58: ...75 4 4 1 Programs 77 4 4 2 Operations 78 4 4 2 1 Forming programs 78 4 4 2 2 Sealing programs 78 4 4 2 3 Cross cuttings 78 4 4 3 Options 1 79 4 4 4 Options 2 80 4 4 5 Temperature settings 81 4 4 6 Forming times 82 4 4 7 Forming times with plug assist 83 4 4 8 Miscellaneous 84 4 4 9 Die opening 85 4 4 10 Depth adjustment 86 4 4 11 Leak detection 87 4 4 12 Traject control 88 4 4 13 Vacuum Settings 8...

Page 59: ...that can display all manner of figures and text just like a PC monitor Instead of having a separate keyboard however the touch screen allows the user to operate the machine simply by touching the icons displayed on screen Careful Only use your hands to operate the touch screen Hard or sharp objects can damage the screen The machine has a great many functions and settings all of which are organised...

Page 60: ...ning Settings Height Adjustment Leak Detection Vacuum Settings Vacuum Times Cross Cutting Times Traject Control Alarms Overview Maintenance Service Program Copy Programs 1 20 Programs 21 40 Program Names Programs 1 20 Program Choice 1 20 Program Choice 21 40 Programs 21 40 Temperature Trends Vacuum Trends Vacuum Graphics All Inputs All Outputs Clock Settings Safety Covers Night Position Gas Flushi...

Page 61: ... machine s current status 2 The retrieval functions such as the green areas after touching them the user gains access to the chosen information 3 The write functions such as the inputting of parameters temperature times etc after touching these parameters can be changed using the keypad 4 On off functions such as the function keys these work like a normal switch and show by a change of color the s...

Page 62: ...he current time Status this status line indicates the status of the machine also all presented failure messages are displayed here as a walking massage behind each other The possible causes of and solutions to the failures displayed can be found in paragraph 7 2 4 2 2 Retrieval and write functions By pressing the buttons in the operator menu see Figure 4 5 the relevant menu is displayed If you pre...

Page 63: ...ow be changed The arrow keys enable the user to navigate from the current input field to other input fields CLR deletes the last shown value Enter gives to the input field the value displayed and the keypad disappears 4 2 2 2 QWERTY Keypad In different menus you can change names or descriptions for example the program names can be changed this way and therefore the QWERTY keypad can be used See Fi...

Page 64: ...tion is switched off Gas Flush Switches on or off the insertion of gas into the packaging This only functions if the packaging program chosen supports it Plug assist Plug assist in forming station can be turned on and off with this button Marking detection Here the photocell has to be switched on for packaging with printed top film This only functions on a machine fitted with a photocell and a fil...

Page 65: ...submenu opens with 1 Operator submenu 2 Sealing temperature settings 3 Forming temperature settings 4 Forming times 5 Vacuum times 6 Crosscut settings 7 Transport settings 8 Discharge 9 Film brake with photocell The main menu can be accessed by pressing MAIN MENU after which a little password screen will appear press the white spot and a keypad will appear After you fill in the right code press EN...

Page 66: ...overs Top view of machine with all used safety covers Reset Reset for all alarm messages Night position Set machine to night position wash position Out of film detection Option to activate the end of film detection 4 3 1 1 Night position To put machine into night position run the film out of the machine switch off all functions activate MANUAL MODE and after this activate Night Position Now the di...

Page 67: ...mory can contain a maximum of 40 The product to be packaged is chosen by touching the program name on the screen Take care that the correct format parts of the chosen program have been installed into the machine If this is not the case the correct packaging cannot be produced and the technical department must be called in to set the machine correctly The retrieved and current program number is dis...

Page 68: ... be changed with 0 01 sec or pause time will be changed with 0 1 sec To change the switch points for vacuum and or gas works in the same way By pressing the button or the pressure will be changed with1 mbar each time Changes made in this screen will not be stored in the current program after a restart the program will start with the original values To change these values for permanent you have to ...

Page 69: ...ter for forming station Vacuum with Sensor and Time for sealing station and vacuum packs Vacuum and gas with sensor and time for sealing station and gas packs Also the type of cross cutting the machine is configured with is visible The left collumn shows the possible sequences for the forming station on the right the sealing station sequence will be found The configuration can only be changed in a...

Page 70: ...e LANGUAGE button in the operator submenu see Figure 4 14 In this screen you can change the language for the touch screen The flag symbol stands for the relative country Press one of the symbols and the relative language will be active Figure 4 14 Language menu ...

Page 71: ...chine The numeric keypad see Figure 4 6 can be used to set the number of production strokes in the current production session The machine stops automatically after the set number of strokes has been reached The machine total production time and the duration of the current production session are displayed in the bottom field In addition the stop time the total time that the machine failed and the t...

Page 72: ...pressing the Explanation Symbols button in the operator submenu see Figure 4 16 This screen shows you the explanation of the symbols which are used and is just for operator information nothing can be changed in this menu Figure 4 16 Explanation of Symbols ...

Page 73: ...4 17 shows the status of the forming station the sealing station the cross cutter and the film transport In addition the menu states whether the inverter is turned on and whether the PLC battery needs to be changed This screen is intended to check the machine s functions If there are any problems the technical department should be contacted Figure 4 17 Overview menu ...

Page 74: ... indicators showing the various safety guards When an indicator lights up green this means that the guard is properly in place If a guard has been incorrectly placed the machine displays an error message which signals which guard it is Once the guard has been properly placed the error can be corrected with the reset button Figure 4 18 Safety guards ...

Page 75: ... Time settings for forming station Miscellaneous Running times chain lubrication Die opening settings Menu for die opening leveling die bottom part Height adjustment Menu for automatic package depth adjustments Leak detection Leak detection in forming station Vacuum settings Vacuum settings for sealing station Vacuum times Time settings for sealing station Cross cutting times Time setting for cros...

Page 76: ...76 NOTE The access to level 2 is accepted for only 15 minutes after this time you go back automatically to operator menu ...

Page 77: ...ent program If you want to copy another program number select in program choice 1 or in program choice 2 the program number you want to copy The button Program name gives entrance to a menu where all program numbers can be renamed just by selecting the program number you want to rename When the qwerty keypad Figure 4 7 appears press button CLR which will clear the existing text and numbers Fill in...

Page 78: ...y the plug Forming after plug plug first and after a delay the forming 4 4 2 2 Sealing programs Vacuum with time evacuation only with time Vacuum with sensor and time evacuation with pressure and time Vacuum and gas with time evacuation and gas only with time Vacuum and gas with sensor and time evacuation and gas with pressure and time 4 4 2 3 Cross cuttings Punch rigid film puncher Guillotine fle...

Page 79: ...vailible cutting options can be selected 1 Position To be able to cut on position with the crosscut positioned with pneumatic activated cylinder Long cutting continuous Rotary knife blades will turn continuously or only during transport Cross cutting 1 2 3 4 The selected cross cutting s will be active during production if button in operator menu is activated Figure 4 22 Options 1 ...

Page 80: ...r synchronised Confirmation station Process with confirmation station inlay support device Temperature Check Temperature control on off machine will not run if the temperature is out of range Close die early Die set will close earlier before end of transport distance or the die set close at the end of transport Out of film detection If selected machine will stop when running out of film Dansensor ...

Page 81: ... arrow Once this happens a small numeric keypad Figure 4 6 will appear on which you can fill in the desired value Press enter and the numeric keypad will disappear The value for the SP has changed Press Save to store the settings into the current program Temperature limit here a tolerance can be set for the SP value If temperature check in Options menu is activated the machine will not run when th...

Page 82: ...rming time time needed to warm up the film throughout When the time has passed the forming valve will open Forming pressure pressure needed to bring the heated film as fast as possible down to the forming plate After reaching the SP the film cooling time will start Film cooling time time needed to cool down the film The bottom die is cooled so the heat can be transferred quickly to the forming pla...

Page 83: ...eeded to warm up the bottom film Forming time vacuum Time for which the forming vacuum valve s will be open Delay forming pressure Time delay before compressed air assists the forming process After this will forming time pressure start Forming time pressure Time that compressed air iassists the forming process Film cooling time Time needed to cool down the film The bottom die is cooled by water so...

Page 84: ...g the process For example to create a situation of an empty conveyor after film advance adjust this time to a certain value for an acceptable result Also the speed for the discharge conveyor after film advance can be changed You can change the value of the set points by pressing the numbers for change a numeric keypad Figure 4 6 will appear fill in the desired settings press enter now the numeric ...

Page 85: ...oth lifting stations are working individually the time for each station can be adjusted independently The speed of the lifting cylinder will effect the timing of these function Be careful always take note of the pack height do not shorten this time so much that the formed packages can not pass through the opening between upper die part and bottom die part The value of the set points can be changed...

Page 86: ...y is not connected to the manual mode and these changes will not be stored into the recent program With reset Depth the bottom plates comes to their upper position for initialization and then return to the desired depth established as a set value The minimum depth is dependent on the design of the bottom plates The difference between minimum and maximum depth is limited to 65 mm The walls or corne...

Page 87: ... The sensitivity can be adjusted with the leak level the lower this value the higher the sensitivity Also the filling position has to be set The input value has to be the number of strokes between forming chamber and filler position with the countstarting at the first stroke after the forming station The value of the set points can be changed by pressing the numbers A numeric keypad Figure 4 6 wil...

Page 88: ...ion has to be set the input value has to be the number of strokes between forming chamber and filler position and forming chamber and sealing station The count starts with the first stroke after forming station This function is only active if button Traject Control is activated lights up in green color If activated the filler signal will be blocked when a leaking pack is at the filler position to ...

Page 89: ...ber the higher the gas pressure into the package Gas time Extra time after switch point gas is reached This will be used in combination with switch point gas Switch point pre fine This is used with a two way central vacuum system Control time vacuum If the vacuum pressure does not reach the switch point vacuum level within this time the machine will give an alarm and stop Control time gas If the g...

Page 90: ...he screen goes back to the screen vacuum settings 4 4 13 2 Vacuum Trends This menu is accessed by pressing the VACUUM TRENDS button in the vacuum settings menu see Figure 4 34 This screen shows you a real time vacuum curve and a stationary curve With the arrows you can look back at the vacuum characteristics Press button return and the screen goes back to the screen vacuum settings Figure 4 33 Vac...

Page 91: ...ing time before the bottom ventilation valves opens Delay ventilation top Waiting time before the top ventilation valves opens Ventilation seal plate Time needed to ventilate the membrane for the sealing plate Pause time Process pause time beginning after the forming process This enables the possibility to synchronize the machine speed for example with a conveyor for product supply The value of th...

Page 92: ...ction time Delay 2 Waiting time before step 3 will start Cross cutting down Step 3 Cutting support goes down after this time the film transport can start with the next transport cycle 4 4 15 2 Punch Operate the change of punch anvil by pressing the punch up down button Remark its only posible to operate this function with covers closed Delay cross cutting up Waiting time before cross cut process w...

Page 93: ...sed Button change of punch anvil is not released The value of the set points can be changed by pressing the numbers A numeric keypad Figure 4 6 will appear fill in the desired settings press enter now the numeric keypad will disappear and the value for the SP has changed Press Save to store the settings in the current program Press return and the screen goes back to the previous menu Figure 4 36a ...

Page 94: ...ection by the photocell mounted at the end of the lanes Number of lanes Number of lanes mounted in the machine Discharge time conveyor Running time that discharge conveyor will run Discharge conveyor speed Running speed for the discharge conveyor You can change the value of the set points by pressing the numbers for change a numeric keypad Figure 4 6 will appear fill in the desired settings press ...

Page 95: ... cuttings First crosscut position Distance in mm between zero point sensor to the first cutting position Distance between cross cuttings Distance in mm between each cross cut Nr of cross cuttings Number of cross cuts in one stroke distance before film advance stops With button Save to Servo the data will be stored into the current program Optional function Figure 4 38 Servo Cross Cutting ...

Page 96: ...ilm advance Contour conveyor height The height of the integrated conveyor can be changed to be level with the discharge conveyor Lane conveyor speed Speed for the discharge conveyor Test Complete cutter makes a complete cycle to control its functions All red LEDs indicate their corresponding position of the cylinder movements The green LED indicates if the discharge conveyor is in place When the d...

Page 97: ...97 4 4 19 Alarms This menu is accessed by pressing the ALARMS button in the main menu see Figure 4 40 This screen shows the last 1000 alarms with a time span Figure 4 40 Alarm History ...

Page 98: ...n after production Can also be activated in the Operator submenu see Paragraph 4 3 1 Flush gas system This function opens the gas valve to flush the gas tank use this function when the gas tank has been disconnected Cleaning chain This function activates the chain cleaning program this is a option Bleeding lubrication By pressing this button it repeatedly activates the chain lubrication cycle to g...

Page 99: ...ow speed Step 2 Chain washing starts and will run for 2 5 minutes Step 3 After washing the program will start to dry the chain for 5 minutes with compressed air Step 4 Chain will be lubricated for 2 5 minutes after drying cycle Step 5 Dies will stay closed program will automatically select the night position after the cleaning cycle At any moment Chain Cleaning Cycle can be interrupted by deactiva...

Page 100: ...ep can be executed The vacuum test is divided into 6 steps Step 1 Die systems close Step 2 Air intake valves close Step 3 Vacuum valves open vacuum in sealing station Step 4 Vacuum valves close vacuum test Step 5 Air intake valves open Step 6 Die systems open Touching the Seal test button during step 4 gives a good picture about the condition of the sealing membranes and the adjustment of the seal...

Page 101: ...er menus After you fill in the right code press enter it will go back to password screen press ok and you are in the relative menu Press button return and the screen goes back to the Main Menu 4 5 Access code The Access code button enables the user to input a code for access to the Main Menu where changes can be made to the machine and the packaging program settings This code may be used only by s...

Page 102: ...troke 110 5 2 5 Re starting the machine 111 5 2 5 1 Machine stop button pressed 111 5 2 5 2 Failure in the safety circuit 111 5 2 5 3 Emergency stop when a format part is closed 111 5 2 5 4 Emergency stop during film transport 111 5 3 Fitting the rolls of film 112 5 3 1 Bottom film 112 5 3 2 Top film 114 5 4 Setting the photocell 115 5 5 Calibrate the photocell 116 5 6 Turning the machine off 117 ...

Page 103: ...s follow the factory instructions In dangerous situations always press the emergency switch immediately You can find more information about the functioning of the emergency switch in paragraph 5 2 Once the emergency switch has been pressed the machine may not be turned on again until the unsafe situation has been corrected Before starting to use the machine place all the protective covers and side...

Page 104: ...on of Transportchain Bell Ray No Tox Food Grade Waterproof Chain Lubricant 2 OL Vat Vacuumpump Busch Bush VM 100 Öl nach DIN 51506 Schmierölgruppe VM Grease lubricant Liftingsystem and Vario die cutter Anderol 783 2 food grade grease Anderol Item ANO7832039 Canada ...

Page 105: ...witch is pressed The machine process is immediately halted and all equipment opens Note the cylinders of the lifting systems and the film punch keep their position when the emergency switch is activated Once the dangerous situation has been corrected the machine can be re set by turning the red button of the emergency switch to the right Then re start the machine using the start up procedure speci...

Page 106: ...inuously and stops when a set number of strokes have been performed or the process is terminated manually Manual film infeed This mode is used when a new roll of bottom or top film is being put in position In this mode only the chain transport is active The staged plans are divided up according to step number description of action and remarks The remarks note the consequences of an action or the r...

Page 107: ...ap must be turned on 6 Check that there is film present Never lift the rolls of film without help To position the film see paragraph 5 3 7 The waste film removal system must be properly aimed Adjustable by the technical department 8 Carry out a visual and manual check to see that the plugs and other couplings are properly fitted in the sockets 9 Adjust the height of the conveyor belt to suit the p...

Page 108: ...nts on and allow the machine 15 minutes to come up to temperature Use the button on the control panel 5 Use the main menu to turn the vacuum pump on Use the button on the control panel 6 Re set the machine with the button on the touch screen or use the stop button Status line indicates ready to start 7 Use the function buttons to turn on the options of the machine which required such as the photoc...

Page 109: ...he heating elements on and allow the machine 15 minutes to come up to temperature Use the button on the control panel 5 Use the main menu to turn the vacuum pump on Use the button on the control panel 6 Re set the machine with the button on the touch screen Status line indicates single stroke 7 Put the machine in manual mode Use the button on the control panel 8 Now start up the process using the ...

Page 110: ...pump on Use the button on the control panel 6 Re set the machine with the button on the touch screen Status line indicates single stroke 7 Use the function buttons to turn on the parts of the machine required such as the photocell the forming station and the cross cutting equipment etc The buttons are in the operator menu such as 8 Turn on any peripherals required such as the filler and the waste ...

Page 111: ...during the forming of the underside or the sealing of the packaging an emergency stop has been made The heating and vacuum pump s will be shut down and the format parts stay at their current position Since safety is in jeopardy the cause of the failure needs first to be traced and corrected before production is continued Then take the following steps Release the emergency switch by turning the red...

Page 112: ...l of bottom film is given in table 8 The main switch must be turned on but no packaging process may be performed Table 8 Staged plan for fitting the bottom film No Action Remark 1 Makes sure you execute all steps according to paragraph 5 2 3 put machine in film infeed mode Via the operator menu 2 Raise the film guide against the infeed roller Make sure it does not fall back WARNING At each stage t...

Page 113: ... the film rollers For the sequence see Figure 5 5 Roll out sufficient film 8 Place the film in the chain clips Draw the film tight when positioning it see illustration 5 5 bottom film 9 Feed the film into the machine a few strokes Check that the film is not running crooked in the machine Use the button next to the film infeed roller to feed the film in slowly see Figure 5 5 10 Choose the required ...

Page 114: ...the film guide if required with extra weights Use help when lifting heavy weights 8 Position the film through the film shafts photocell and film brake to the bottom film Sequence see Figure 5 6 Roll out sufficient film 9 Fix the start of the top film to the bottom film with a piece of adhesive tape Do this on the infeed side of the top film infeed shaft Avoid making folds in tape or film Position ...

Page 115: ...nts taken by the photocell This means that the photocell needs to be appropriately adjusted Follow the adjusting steps below Ensure that both upper and bottom films are placed in the machine as described in paragraph 5 3 Turn the photocell on via the touch screen Loosen the star grip see Figure 5 7 and aim the photocell at the marking across the machine Set the position by tightening the star grip...

Page 116: ... acquires the switching point for the red and green emissions don t move the mark during this phase Output OFF state acquisition BKGD Place the background into the emission spot and press the BKGD button the green LED blinks once The sensor acquires the switching point for red and green emissions don t move the background during this phase If the green LED lights permanently ON a safe operation ha...

Page 117: ...e monitored Then if a failure occurs corrective measures can be taken quickly and the cause of the problem is easier to trace A number of important points on the machine are the film rolls the formed packages the filled packages and the waste film removal unit The lower and top films must be firmly stretched and more or less equal lengths must be clamped in the chain on both sides The formed packa...

Page 118: ... Figure 5 9 It is not permitted to have body parts under the covers 5 8 Energy saving operation In order to lessen the burden on the environment it is a good idea not to leave the machine turned on needlessly Use every opportunity to shut the machine down partially or completely Figure 5 9 Loading area ...

Page 119: ...ansers 120 6 1 2 Washing setting 121 6 1 3 Disinfecting and removing calcium deposits 121 6 2 Maintenance procedures 121 6 3 Maintenance instructions 126 6 3 1 Conveyor chain 126 6 3 2 Lifting stations 128 6 3 3 Hard foil stamp 130 6 4 Recording the maintenance and cleaning logbook 134 ...

Page 120: ... injury and damage to the machine 6 1 1 Cleansers Cleansers are used to clean the machine Not all cleansers are suitable for the machine So follow the guidelines below during cleaning activities Read the supplier s instructions before use Use cleansers with a pH value between 6 and 9 5 Acid cleansers can discolor the surface of components Use a low pressure foam cleaning unit max 6 bar water press...

Page 121: ...i corrosives or medicinal oil 6 2 Maintenance procedures The maintenance system consists of two parts 3 procedures that describe the actions to be undertaken Each procedure describes a number of activities that have to be carried out A logbook A record is kept in the logbook of who carried out a particular activity The logbook also has space for remarks e g activities not performed or parts exchan...

Page 122: ...rns the machine on during cleaning operations A number of parts of the machine carry a higher hygiene risk see Figure 6 1 Always clean these very carefully Figure 6 1 Points requiring special attention 1 The angled connections at the support legs 2 The chain guide 3 The edges where the cabinet connects to the frame 4 Flat horizontal parts of the machine 2 1 4 3 ...

Page 123: ...rs and side plates if so required WARNING format parts remain hot up to 1 hour after being shut down 5 Check the seals between upper and lower dies for defects Remove the covers if necessary Inspect visually If a defect is found call the Technical Department in 6 Set the main switch on the control cabinet to 1 7 Replace all protective covers and side plates on the machine See paragraph 4 2 1 for t...

Page 124: ...s sensitive to water such as motors control panel labeling machines and vacuum pump Fix the film in place with adhesive tape if necessary but ensure that the parts cannot flood Avoid as far as possible any direct contact with water ...

Page 125: ... skin protection against cleansers compressed air waste bin chain oil small brush screw driver 1 protective plates 2 side plates 3 bottom film infeed roller 4 product support bars 5 support tray 6 longitudinal cutter 7 crosswise cutting Figure 6 3 RE20 1 1 2 3 4 4 5 6 7 Transport chain Chain clips ...

Page 126: ...hain tension adjustment The chain tends to stretch a certain amount immediately after installation of the chain This is caused by running in of the components After this initial extension about 0 05 the chain will uniformly extend somewhat as a result of normal wear This must be compensated by for instance a chain tensioner In order to maintain correct chain tension it is necessary to check it reg...

Page 127: ...chain have been cleaned then the chain must always be lubricated again Bear in mind that after cleaning moisture and cleaning agents can have penetrated the chain guide This can be removed by running the chain for a period The chain can then be lubricated The conveyor chain can be lubricated in two ways Manually with a brush or oil can The lubricant must penetrate between the pin bush and bush rol...

Page 128: ...damage contamination and corrosion Remove any film and or product residue Both types of lifting station are fitted with synthetic sleeve bearings for linear vertical guidance These sleeve bearings are maintenance free Only the guide shafts need checking for contamination and or damage Each lifting station has twelve lubrication nipples A lifting station can be fitted with a central lubrication sys...

Page 129: ...the entire lifting station once a week This lubricating scheme applies for machines operating under normal operating conditions The lubricating intervals must be adapted depending on conditions and operating intensity If in doubt consult the distributor Lubricant specifications The bearings are lubricated with Anderol 783 2 food grade ex factory ...

Page 130: ...due If applicable use the key switch for safe operation of the hard foil syamp Read the instructions for more information on the key switch If in doubt consult the distributor Hard foil stamp The hard foil stamp has ten lubricating nipples The following figures show where the the lubricating nipples are located Figure 8 Stamp lubrication points Figure 9 Bearing bush lubrication points ...

Page 131: ...ubricating nipples for the SS bearing bushes are then moved to the side of the hard foil stamp two of these lubricating nipples are visible on Figure 9 Take note the other six lubricating nipples must still be lubricated in the normal manner ie manually Lubrication Repak advises fully lubricating the stamps once a week This lubricating scheme applies for machines operating under normal operating c...

Page 132: ...o remove remains of waste materials from the machine and rinse the spots once again 10 X Remove calcium deposits from parts affected Use only moderate amounts of decalcifier Follow the instructions given in paragraph 6 1 11 X Clean the decalcified parts thoroughly with water 12 X Remove the film used for cleaning purposes See procedure 6 1 step 11 13 X Dry the entire machine with compressed air 14...

Page 133: ... driver No Action Remark 1 Replace all components that have been removed 2 Replace all safety covers and protective systems See paragraph 2 4 3 for positioning the side plates 3 Press the Re set button 4 Press the washing setting button The machine turns the washing procedure off The working systems open automatically See paragraph 6 1 2 5 The machine is now ready to operate If so desired the mach...

Page 134: ...134 6 4 Recording the maintenance and cleaning logbook Type of maintenance Date Name Signature Remarks Daily weekly monthly ...

Page 135: ...135 Contents 7 Overview of status lines 136 7 1 Environmental factors 136 7 2 Overview of status lines 137 7 3 Defects affecting the film 139 8 Explanatory list of words 140 9 Appendix 144 ...

Page 136: ...al conditions required to have the machine function properly Table 11 Environmental factors Characteristic Possible problem Cause Solution The status line reports overheated components The surrounding temperature is over 40 C 104 F Some parts of the machine are over heating Ensure that the surrounding temperature is lower The touch screen or another electrical systems fails There is too much humid...

Page 137: ...r s range 09 Temperature much too high The temperature of the sealing or forming units is too high 11 No air pressure The compressed air system is not under pressure Check that the supply hose is properly connected If not call in the technical department 12 No water pressure The cooling water system is not under pressure 14 No central vacuum present The machine has no vacuum Call in the technical ...

Page 138: ... too long to reach the set value for gas pressure Check gas pressure in system or contact technician 54 Dansensor 1 Dansensor has failed Call in the technical department 64 Safety Cover Form station rear is open The safety cover at the back of the forming station the infeed side is open Place the cover in its proper position see paragraph 4 2 1 and start the machine up as specified in paragraph 5 ...

Page 139: ...d because the manual operating mode is turned on This mode can be switched off in the main menu Standby Ready to start The machine is ready to start automatic operation This is normal For more information on this mode see paragraph 5 2 2 Run RE20 in motion The machine is running This is normal See paragraph 5 6 to stop the machine 1 are optional functions 7 3 Defects affecting the film A defect or...

Page 140: ...binet containing all the electronic and pneumatic systems required for powering the machine s processes Drive module This module contains the film chain drive E L S 1 cross web labeler brand name ELS E L S 2 cross web labeler brand name ELS Emergency switch module control panel Red button on the control that stops the machine instantly when pressed Exit side The side of the machine where the packa...

Page 141: ...hine The specific design of this wheel causes the transport chain clips to open here so that the bottom film can be fed into the machine Infeed side The side of the machine where the bottom film is fed in Inverters Frequency regulator for the main drive Lifting system or lifting gear System that raises and lowers the seal die and vacuum die to and from the film Machine This indicates the RE20 deep...

Page 142: ...ing wounded by a moving part PV Present Value This is the current value Rotating blades Module that cuts the packages loose in a lengthwise direction Safety cover Fixed and removable covers on the outside of the machine that protect the operator from moving parts Seal module or seal station Module where the packaging is sealed Sealing Melting the top film to the bottom film so that the packaging i...

Page 143: ...h buttons can be activated by touch The touch screen is part of the control panel Transport chain Chain fitted with clips that clamp the film fast Feeds the film through the machine This chain is on the cabinet side and the operation side of the machine Top film infeed shafts This is the shaft onto which the film roll is placed and along which the film is guided into the machine Vacuum Low pressur...

Page 144: ...144 9 Appendix TI 14 025 Vacuum pump warm up and after running TI 14 032 Declaration of compliance for food contact ...

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Repak RE20, User Manual

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