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WF30T

Case Former

Troubleshooting & Repairs

- 10-95 -

10 TROUBLESHOOTING & REPAIRS

10.1 Safety

Safety Features

To safely work on the machine, disconnect the compressed air supply and power supply. The
guard doors around the WF30T will ensure that you do not accidentally enter the machine’s
working cell while its components are energized. Never attempt to disable any of the safety
features or enter in through the discharge end while the machine is still powered.

An

‘EMERGENCY STOP’

button is provided to immediately halt all machine operation by cutting

off air supply and electrical power. This button should be pushed

IN

to stop the machine in case

of an emergency.

Precautions

•

The WF30T Case Former is equipped with safety interlocks. Do not attempt to disable

the interlocks when repairing the machine.

•

Do not use the

‘EMERGENCY STOP’

button as the sole means of isolating power to the

machine. Disconnect power at the main breaker panel and lock it out before undertaking
repairs.

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Summary of Contents for WF30T

Page 1: ...WF30T Case Former WEXXAR WF30T CASE FORMER Operation and Service Manual 10101 Nordel Court Delta B C V4G 1J8 Canada Telephone 604 930 9300 Fax 604 930 9368 WF30T Rev 1 15 ...

Page 2: ...WF30T Case Former ...

Page 3: ...EVELING AND CONVEYORS 2 7 2 5 1 Location 2 7 2 5 2 Leveling 2 7 2 5 3 Discharge Conveyor 2 8 2 6 SERVICE CONNECTIONS 2 8 2 6 1 Compressed Air 2 8 2 6 2 Electrical Power 2 9 3 COMPONENT IDENTIFICATION 3 10 3 1 MAJOR COMPONENTS ALPHABETIZED 3 12 3 2 PIN AND DOME TECHNOLOGY 3 16 4 THEORY OF OPERATION 4 17 4 1 SEQUENCE OF OPERATIONS 4 17 4 2 SENSORS 4 19 4 2 1 Optical Proximity Sensors 4 19 4 2 2 Indu...

Page 4: ...ESS ADJUSTMENT DIMENSION F 7 68 7 9 1 Jawplate F Adjustment 7 69 7 9 2 Caliper F Adjustment 7 70 8 OTHER MACHINE ADJUSTMENTS 8 72 8 1 SAFETY 8 72 8 2 STABILIZER BARS AND PINBLOCKS 8 73 8 3 MAGAZINE PUSHER 8 74 8 4 SENSOR LS 7 ADJUSTMENT 8 75 8 5 MINOR FLAP FOLDERS 8 75 8 6 TESTING THE SIZE ADJUSTMENTS 8 75 8 7 QUICK SIZE CHANGE GUIDE 8 77 9 MACHINE MAINTENANCE 9 79 9 1 SAFETY 9 79 9 2 MAINTENANCE ...

Page 5: ...pical Pneumatic Issues 10 106 10 7 LED STATUS TABLES 10 107 10 8 REPAIR PROCEDURES 10 109 10 8 1 Pneumatic Cylinder Repairs 10 109 10 8 2 Magazine Repairs 10 110 10 8 3 Forming Head Bearing Repairs 10 110 10 8 4 Major Flap Folder Repairs 10 110 10 8 5 Solenoid Valve Repairs 10 111 10 8 6 Conveyor Drivebelt Repairs 10 111 10 8 7 Drivebelt Bearings Repairs 10 111 10 8 8 Gearmotor Repairs 10 111 11 E...

Page 6: ...imension G Adjustment 7 68 Table 25 Dimension F Adjustments 7 71 Table 26 Magazine Pusher Adjustment 8 74 Table 27 Mechanism HOME Positions 8 76 Table 28 Full Cycle Sequence 8 76 Table 29 Sensor Adjustment References 8 77 Table 30 Dimension Adjustment Reference 8 78 Table 31 Machine Inspection 9 80 Table 32 Cleaning the Machine 9 81 Table 33 Magazine Pusher Maintenance 9 84 Table 34 Feedbelt Maint...

Page 7: ...d normal 10 105 Table 55 Forming head not moving 10 105 Table 56 Jaw not moving 10 106 Table 57 PLC Input LED Status Table for Jog Step Sequence 10 107 Table 58 PLC Output LED Status Table for Jog Step Sequence 10 108 Table 59 Operating Parameters 11 112 Table 60 Training Outlines 12 114 Table 61 Performance Checklists 12 116 ...

Page 8: ...n Buttons 5 30 Figure 5 12 Box Settings Screen 5 30 Figure 5 13 Box Dimension Selection Keypad 5 31 Figure 5 14 SELECTED CPM AND CPM RANGE Status Indicators 5 31 Figure 5 15 JOG CONTROL Button 5 31 Figure 5 16 Jog Control Screen 5 32 Figure 5 17 Blinking Sensor LS6 5 32 Figure 5 18 Error Identification Screen 5 32 Figure 5 19 MACHINE CYCLE JOG Button 5 33 Figure 5 20 SETUP Button 5 33 Figure 5 21 ...

Page 9: ...tton 5 45 Figure 5 65 PREVIOUS Button 5 45 Figure 7 1 Dimensions on Left and Right Hand Cases 7 56 Figure 7 2 Case Measuring Scale 7 56 Figure 7 3 Mast Assembly Components 7 57 Figure 7 4 Dimension B 7 58 Figure 7 5 Dimension B Adjustments 7 58 Figure 7 6 Adjusting the Collar Assembly 7 59 Figure 7 7 Dimension E 7 60 Figure 7 8 Head up Latch 7 60 Figure 7 9 Dimension E Adjustments 7 60 Figure 7 10...

Page 10: ...lates 8 78 Figure 9 1 Conveyor Belt Tensioning 9 87 Figure 9 2 Inductive Sensor Adjustment Range 9 89 Figure 9 3 Mast Assembly Showing Guide Wheels 9 93 Figure 9 4 Discharge Pusher Sealed Guide Wheels 9 94 Figure 9 5 Mast Assembly Sealed Guide Wheels 9 94 Figure 14 1 Beacon Lamp Status Indicators 14 120 ...

Page 11: ...please contact our Service Center before proceeding While every effort has been made to ensure the completeness and accuracy of this manual WEXXAR assumes no responsibility or liability for any losses or damages resulting from the use of the information contained in this document Due to technical advances and improvements some of the information contained in this manual may be changed or modified ...

Page 12: ...ith case size adjustments as well as testing and troubleshooting Chapter 8 describes machine calibration procedures not dealt with in Chapter 7 Chapter 9 is for users who maintain equipment or systems It provides the safety guidelines a maintenance schedule the procedures for maintenance and lubrication and a list of maintenance parts Chapter 10 is for qualified repair technicians and provides the...

Page 13: ...ual we italicize the link and use single quotes For example See Section 6 Operating Procedures Please note that some of the some of the pictures in this manual may differ slightly from your machine This symbol alerts you to a risk of personal injury due to mechanical or pneumatic operation This symbol indicates that an electrical hazard may be present It may be used in lieu of the wording caution ...

Page 14: ...ctive envelope while the machine is in operation An EMERGENCY STOP button immediately halts all machine operations by cutting off air supply and electrical power This button should be pushed IN to stop the machine in case of an emergency WARNING The instructions in this manual are not intended to cover all of the details or variations in equipment or to provide for every possible contingency to be...

Page 15: ...s CSA C22 2 No 14 95 Industrial Control Equipment ANSI Z535 4 2002 Product Safety Signs Labels ANSI B155 1 2000 for Packaging Machinery NEMA 12 UL listed standard electrical control 1 3 General Precautions Your WEXXAR packaging machine is a rugged piece of industrial machinery It is equipped with various guards and other safety features but it must be treated with respect at all times to avoid the...

Page 16: ...ng parts as they may move quickly when the pressure is reapplied Make sure that no other people are in a dangerous position when switching the compressed air on 1 6 Electrical Power All WEXXAR machines use electrical power Switch off the main power disconnect switch on the control panel and lock it out before attempting service work outside of the electrical enclosure Before performing service wor...

Page 17: ...nt cautionary labels for every conceivable workplace hazard including electrical pneumatic and mechanical hazards Please pay particular attention to the cautionary labels found on the machine Examples of cautionary labels are shown below 1 11 Touchscreen Cautionary Alerts The WF30T also features cautionary alerts on the Human Machine Interface HMI touchscreen 1 12 Lubricants etc Read the attached ...

Page 18: ... indoor environment free of conductive contaminants Do not let the any areas of the unit adjacent to electrical components come in contact with water Do not stand beverage containers on the electrical panel or on any surface adjacent to electrical components This system is not intended for external use unless it has been specifically modified for that purpose This unit is rated in accordance with ...

Page 19: ...ughly for shipping damage and ensure that all mechanisms move freely Report any shipping damage immediately to your Carrier Check spare parts kits change parts and any other loose items against the packing slip and report any errors or omissions to your WEXXAR agent for corrective action The crate should be dismantled and all packing materials and shipping ties should be removed Do not disassemble...

Page 20: ... on one end so that you always work to the same bubble line and with the concave side down if there is one Open the bi fold doors and position the spirit level along the length of the main frame to level one side of the machine Adjust the machine leveling feet on this side of the machine as appropriate to centralize the bubble between the parallel lines Position the spirit level on the main frame ...

Page 21: ... end of the machine The air supply should be clean and dry and the air line should have a minimum inside diameter of 3 4 for flexible tubes or 1 for steel tubes With the electrical power OFF open the manual shutoff valve and check that the regulator is set to a pressure of 90 PSI After connecting the electrical power see Section 2 6 2 switch the electrical power ON all cylinders should revert to t...

Page 22: ...d all access doors are closed switch the main disconnect switch ON Check that the EMERGENCY STOP button is in the OFF position Press the RESET button on the control panel Ensure that the touchscreen is displaying the Main Control screen and press the START button The case blank motor and the drive motor should both be ON If desired install the remote demand sensor at a suitable location on the dis...

Page 23: ...ENT IDENTIFICATION Figure 3 1 Component Overview Sliding Frame Management Beacon optional Operator Side Guard Doors Tape Head Assembly Main Frame Sliding Guard Doors Drive Motors Case Separator Collar Stabilizer Bars Jawplates Pinblocks Mast Mast Guide Track ...

Page 24: ...ide View Figure 3 3 Left Hand Infeed View Leveler typical Control Panel Electrical Enclosure Feedbelts Flap Folders Side belt Conveyors Discharge Pusher Safety Interlocks Filter Regulator Forming Head Magazine Assembly Injector Magazine Pusher Discharge Pusher Guide Track ...

Page 25: ...any other buttons and switches for operating the machine It houses the PLC Programmable Logic Controller and other electrical components 6 DC Power Supply The DC Power Supply is a device that delivers 24V DC power for the machine s control system 7 Discharge Pusher The Discharge Pusher is a pneumatically driven assembly that moves horizontally to advance the formed case out of the major flap folde...

Page 26: ...mbly which moves forward when the machine s air pressure is switched OFF Its function is to hold the forming head in the UP position in order to make jam clearing easier 19 Hinged Guard Door The Hinged Guard Door also called the Operator Side Guard Door provides access to the forming area of the machine The machine immediately stops if this or any other door is opened during operation 20 Inductive...

Page 27: ...of the case so the pins can be withdrawn from the top 32 Manual Shutoff Valve The Manual Shutoff Valve is a ball valve mounted at the infeed end of the regulator which permits the secure shutdown of the machine s pneumatic system The valve can also be locked out which may be required by local or federal regulations 33 Mast The Mast is a vertical structure that supports and guides the forming head ...

Page 28: ... Sliding Frame The Sliding Frame assembly slides over the main frame and changes position during adjustment to fit the length of the case being processed 43 Sliding Guard Doors The Sliding Guard Doors provide easy access to the forming head and other assemblies The machine stops immediately when any door is opened during operation 44 Solenoid Valve The electrically operated solenoid valves control...

Page 29: ...orrugated case material The result is clamping of the outer skin giving unparalleled grip on the case panels Pin and Dome modules are mounted on opposing hinged plates After each case blank is separated from the magazine stack it is thrust upward between these plates and onto the Pin and Dome modules gripping the case on two sides at one corner The plates then open to an angle of 90 opening the ca...

Page 30: ...ed in the case formation are 1 Case Supply A case magazine holds the folded cases ready for erecting and feeds them into the machine The cases stand edgewise on two red feedbelts which steadily move them towards the case forming section where they are selected one at a time for processing The magazine pusher is also part of the feed system It applies constant pressure to the top rear of the case s...

Page 31: ...ing the folding of the case s minor flaps 6 Major Flap Folding A pair of major flap folders receives the bottom major flaps into slots as the forming head descends to the fully DOWN position When the case is fully DOWN the major flap folders rotate to fold the case s major flaps about half way and secures the case from vertical movement The forming head now moves to the UP position pulling the pin...

Page 32: ...agnetic field They monitor the position of the machine components and are used to verify if a motion has been completed before proceeding Table 2 Inductive Sensors Sensor Name Status Part Condition LS 1 ON 01 199 Head UP LS 2 ON 01 199 Jaws CLOSED LS 3 ON 01 265 Injector DOWN LS 4 ON 01 199 Jaws OPEN LS 5 ON 01 198 Pusher BACK LS 6 ON 01 199 Head Partially DOWN LS 8 ON 01 265 Major Flap Folded LS ...

Page 33: ...ine conditions Table 5 Magazine Management Sensors Sensor Name Status Part Condition LS 13 OFF 02 707 Empty Magazine LS 14 OFF 02 707 Low Magazine 4 3 Interlock Switches The interlock switches are used to ensure that all doors are CLOSED while the machine is operating Table 6 Interlock Switches Sensor Name Status Condition DS 1 OPEN Magazine Slide Door OPEN DS 2 OPEN Bi fold Door OPEN DS 3 OPEN Ou...

Page 34: ...adhesive tape application and detects faulty conditions A set of optical and inductive sensors monitors the condition of the tape applicator Table 7 Tape Management System Sensors Sensor Name Status Part Condition LS 12 ON 01 198 No Running Tape inductive LS 15 ON 02 707 Case at Tape Head optical LS 16 ON 02 707 Low Tape optical ...

Page 35: ...WF20T Case Former Component Identification 4 22 4 5 Sensor Locations Figure 4 1 Sensor Locations Part 1 LS 1 LS 2 LS 3 LS 4 LS 6 LS 17 LS 18 LS 12 LS 15 LS 16 optional ...

Page 36: ...WF20T Case Former Component Identification 4 23 Figure 4 2 Sensor Locations Part 2 LS 5 LS 7 LS 8 LS 9 LS 11 LS 13 LS 14 optional ...

Page 37: ... can be sped up or slowed down without having to manually adjust each valve setting Servo valve V1 Jawplate Assembly is mounted on a connecting plate which is mounted on the side of servo valve V3 Mast Assembly on the sliding frame assembly near the mast on the rear of the machine Servo Valves have 2 inputs The first is a supply of 24VDC which powers the valve and allows it to move its shuttle aro...

Page 38: ...quire more energy to fold the flaps correctly and to perform other pneumatically driven functions Case Size and Weight A significant increase in case size or weight will also change the speed of the solenoid driven cylinders as they require more energy to drive the cylinders For solenoid valve troubleshooting see Section 10 6 Pneumatic Troubleshooting 4 6 4 Non Lube Pneumatic System Wexxar s non l...

Page 39: ...ired by local regulations or company policy lock out the electrical power and air supply before proceeding 4 If the machine has stopped mid cycle open a guard door and remove any case corrugate 5 Inspect the machine for air leaks 6 Make sure that the air compressor is operating properly and that the pneumatic supply hoses are not leaking 7 Pull OUT the EMERGENCY STOP button close the guard door if...

Page 40: ...sconnect switch turns the main electrical power to the machine ON or OFF it can be locked in the OFF position for safety during maintenance operations 2 RESET Button The white RESET button returns the machine to a state where it is ready to resume operation after an emergency stop or other machine fault 3 EMERGENCY STOP Button The EMERGENCY STOP button immediately cuts off electrical and air suppl...

Page 41: ...the Warning Message display immediately below the machine status messages The cautionary messages include warnings that machine components may be running too fast or too slowly 5 MAIN CONTROL Button This button is located to the bottom left of the touchscreen when the machine is in JOG mode Pressing the MAIN CONTROL button will take the machine back to the Main Control screen In the bottom left ce...

Page 42: ...ll be replaced with a STOP button NOTE When the START button is pushed the JOG CONTROL and SETUP buttons disappear until the STOP button is pushed and the machine stops its cycle 7 STOP Button The STOP button stops the automatic machine cycle If the STOP button is pressed while the machine is in the middle of a case forming cycle the machine finishes forming the case in process and then halts any ...

Page 43: ... Total Number of Cases value is touched a pop up window appears displaying the text Are you sure you want to reset the CPM Counter Press OK to confirm the change When this value is changed the actual CPM value will become 0 10 Selected CPM Below the Actual CPM value is the Selected CPM value This value is not touch sensitive and cannot be changed on the Main Control screen 11 CASE DIMENSIONS Butto...

Page 44: ...4 Selected CPM and CPM Range To change the Selected CPM touch the blue value of the Selected CPM to the right of the title A keypad will appear on the left of the screen showing the maximum and minimum dimensions available for the selected measurement Enter in a value between these two parameters and press ENTER The CPM range value cannot be changed in this display To return to the Main Control sc...

Page 45: ...uching the resulting photo will return the touchscreen to the Jog Control screen For troubleshooting instructions please refer to Section 10 Troubleshooting Repairs The status indicator in the lower right hand corner of the display is labeled MTR Touching this status indicator will display a photo of the side belt drive motors If the MTR status indicator is blinking one of the side belt drive moto...

Page 46: ...settings for purposes such as activating or deactivating either the REMOTE DEMAND sensor or DRY CYCLE operation for the purpose of troubleshooting press the SETUP button in the bottom right hand corner of either the Jog Control or Main Control screens The SETUP button disappears from the Main Control screen when the machine is running in CYCLE mode 19 SETUP Screen The Setup screen provides access ...

Page 47: ... DEMAND Toggle Switch Located in the right center of the Setup screen this toggle switch turns the REMOTE DEMAND feature ON or OFF The REMOTE DEMAND feature is used to halt machine operation if cases are not moving away from the machine on the downstream conveyor thus avoiding jams It also matches case forming output to the rate of consumption by downstream processes To enable the REMOTE DEMAND fu...

Page 48: ... operator for a password Touch the blank field in the Password window to bring up an Alphanumeric Keypad window Type the required password To enter the password into the Password window touch the ENTER key Then touch the OK button in the Password window If you enter an invalid password an error message will display Touch OK to remove the error message and input a valid password Touch the SETUP in ...

Page 49: ...creen to return to the Setup screen NOTE The data fields on this screen are read only Values are not touch sensitive The Machine Feedback screen is used for machine diagnostics 26 TROUBLESHOOTING Button The TROUBLESHOOTING button is found on the upper right hand side of the SETUP screen to the right of the MACHINE FEEDBACK button The Troubleshooting screen provides access to the machine s PLC Prog...

Page 50: ...e illuminated Note not all of the function indicators are active Touch the PREVIOUS button in the bottom right hand corner of the PLC Inputs screen to return to the Troubleshooting screen or press the MAIN CONTROL button in the bottom left hand corner of the screen to bring up the Main Control screen Figure 5 36 PLC Inputs Screen Figure 5 37 Illuminated PLC INPUTS Status Indicator Figure 5 38 Samp...

Page 51: ...e adjustments should be made in response to the red machine fault messages in the Machine Alarm display at the top of the PLC Inputs screen and the amber cautionary messages which scroll through the Warning Message display below the Machine Alarm display These cautionary messages include warnings when a machine mechanism is operating too fast or too slowly 31 PLC OUTPUTS Button In the center right...

Page 52: ... to the Setup screen Touch the MAIN CONTROL button in the bottom left hand corner of the screen to bring up the Main Control screen 33 SETUP GUIDE Button On the upper right hand side of the Settings screen is the SETUP GUIDE button 34 SETUP GUIDE HELP Screen The SETUP GUIDE HELP Screen features nine buttons which access illustrated instructions for eight different aspects of the machine setup They...

Page 53: ...p Touching the instructions screens anywhere else will bring up the SETUP GUIDE HELP screen again Continue the setup guide sequentially for Steps 2 through 8 before starting the machine 35 CASE SIZE ADJUSTMENT Detail Screen Whenever necessary photos are used to illustrate steps in the case size adjustments Figure 5 45 Sample Setup Guide Detail Screen Use the Back and Forward buttons to navigate th...

Page 54: ...h the blue numerals of this value A TENKEY Keypad window will appear Touch in the new empty magazine count value and then touch ENTER This will enter the new EMPTY MAGAZINE value The acceptable range for this value is 0 25 Use the same method to enter the remote demand relay time in milliseconds The acceptable range for this value is 0 10000 To exit this screen touch the MAIN CONTROL button in the...

Page 55: ... alter the jaws homing value touch the blue numerals of the HOMING VALUE button Touching this value will bring up a Ten key keyboard which can be used to change the value Touch ENTER to set the new jaw homing value 40 Current Value Display Immediately above the HOMING VALUE button is the jaws Current Value display This value is not touch sensitive but it will change automatically to display actual...

Page 56: ...s of the HOMING VALUE button Touching this value will bring up a TENKEY keyboard which can be used to change the value Touch ENTER to set the new forming head homing value 44 Current Value Display Immediately above the HOMING VALUE button is the jaws Current Value display This value is not touch sensitive but it will change automatically to display actual real time values from the PLC when the mac...

Page 57: ...oggle the CYCLE MODE button which will activate JOG mode When this is done the button will be replaced with a blue JOG MODE button Users can return to CYCLE mode by touching the JOG MODE button thereby restoring the CYCLE MODE button Any changes that are made to the settings on the Servo Settings screens are immediately applied to the machine If the machine is in CYCLE mode the changes are impleme...

Page 58: ...CLE OFF button Press the PREVIOUS or MAIN CONTROL buttons to exit either of the Servo Settings screens HIGH SPEED SERVO SETTINGS Table 9 High Speed Servo Settings JAWS FORMING HEAD CURRENT VALUE 15700 15700 HOMING VALUE 17500 20000 OPEN CLOSE OPEN CLOSE INITIAL SPEED 32767 00000 20000 11900 RAMP RATE 01525 00800 00050 00020 LOW SPEED SERVO SETTINGS Table 10 Low Speed Servo Settings JAWS FORMING HE...

Page 59: ... system surrounds the area known as the restrictive envelope and covers the entire range of possible machine motion For your safety you should never try to bypass the perimeter guarding system or enter the restrictive envelope while the machine is in operation An EMERGENCY STOP button is provided to immediately halt all machine operation by cutting off air supply and electrical power This button s...

Page 60: ...ar Is the electrical power disconnect switch turned ON The Black operating lever should be in a vertical position Are all EMERGENCY STOP buttons including auxiliary EMERGENCY STOP buttons in the OUT position Turn clockwise or pull out to release Is the tape applicator on the WF30T properly installed loaded with a tape roll and ready to go The end of the tape should be on the front roller with the ...

Page 61: ...if the REMOTE DEMAND sensor is clear Verify that the screen is displaying the Main Control screen If not press the MAIN CONTROL button in the bottom left of the screen 6 2 2 Start up Procedures After completing the procedures outlined in Section 6 2 1 Preliminary Checks start the machine as follows 1 Press the RESET button once READY appears on the display and air pressure will now be applied to t...

Page 62: ...racking properly They should be centered on the drive pulley properly tensioned and in reasonably good condition Verify that the magazine pusher valve is ON and that the pressure is set to between 20 and 35 PSI CYCLE Operation Press the SETUP button in the bottom right of either the Main Control or Jog Control screens If the button reads REMOTE DEMAND OFF there is no need to press the button as th...

Page 63: ...L button on the bottom left of the screen to enter into JOG mode Pressing the MACHINE CYCLE JOG button on the Jog Control screen will cycle through each machine sequence one step at a time for each push of the button 6 3 Monitoring 6 3 1 Monitoring Machine Operation The WEXXAR WF30T is completely automated It requires very little monitoring once it is running Monitoring the machine involves Ensuri...

Page 64: ...ifies loading Do not let the magazine quantity get too low If there are fewer than 12 of cases in the magazine reloading may require stopping the machine This is because the magazine pusher can interfere with the case separator and or the guarding when insufficient cases are present If your machine is equipped with the optional low magazine sensor a warning will be emitted when it is necessary to ...

Page 65: ...witch the magazine pusher valve back to ON Remove any banding straps that may be around the case bundles 6 4 Clearing a Case Jam The WEXXAR Model WF30T Case Formers will provide reliable trouble free performance on a wide variety of case sizes Occasional jams are not uncommon but frequent jamming can usually be traced to a particular reason such as incorrectly set machine adjustment and corrected ...

Page 66: ...up Check the S box for Satisfactory Performance and US box for Unsatisfactory Performance Table 15 Clearing Jams Clearing Jams S US Press the RESET button Press the EMERGENCY STOP button Wait until air pressure has fully exhausted and all mechanisms are stationary before proceeding Open the guard door for access to the jammed case Remove all jammed case corrugate by hand Make sure the first case i...

Page 67: ...the machine after an emergency stop is more complex Most likely the case that was being formed will be wasted and have to be removed manually Refer to Section 6 4 Clearing a Case Jam 3 Open a Guard Door Opening a guard door will stop the machine rapidly regardless of where the machine is in its operating cycle similar to actuating the EMERGENCY STOP button 4 Disconnect Switch Turning OFF the disco...

Page 68: ...he entire range of possible machine motion For your safety you should never try to bypass the perimeter guarding system or enter the restrictive envelope while the machine is in operation An EMERGENCY STOP button is provided to immediately halt all machine operation by cutting off air supply and electrical power This button should be pushed IN to stop the machine in case of an emergency Precaution...

Page 69: ...r words the first adjustment in the sequence is Dimension B rather than Dimension A as it is the start of the most efficient adjustment procedure on the machine itself The next adjustment is for Dimension E as it is located right next to the B adjustment and so on Begin by measuring the key dimensions of the case as shown in Figure 7 2 A scale is provided on the magazine end of the sliding guard d...

Page 70: ...Adjustments 7 57 Figure 7 3 Mast Assembly Components E Dimension Adjustment Scale B Dimension Adjustment Scale E Adjust Knob E Adjust Locking Handles Mast Assembly Collar B Adjust Hand Crank B Adjust Locking Handles Head Up Latch ...

Page 71: ...gure 7 3 3 First retighten the collar quick adjust handle located behind the column on the side opposite the B adjustment crank 4 Then retighten the second collar quick adjust handle Always check the setting afterwards as the collar sometimes moves slightly when this is done 5 You can check the collar setting by pushing a flat case down into the caliper slot onto the injector drive plate The top o...

Page 72: ...ent Dimension B S US Measure Dimension B against the scale Unlock the two quick adjust handles that secure the collar assembly Use the crank handle to set Dimension B Retighten the quick adjust handles Test the setting by pushing a flat case into the caliper slot and seeing how it fits Figure 7 6 Adjusting the Collar Assembly Calipers Case Separator Injector 6 mm Clearance Separator Up Separator D...

Page 73: ... as follows 1 Ensure that the case forming head is resting on the head up latch Do this easily by pressing the EMERGENCY STOP button while the machine is stopped normally 2 Loosen the two yellow clamp handles which clamp the forming head assembly to the two 8 5 diameter 16 mm driverods 3 Using the yellow knob handle provided move the drive rods to achieve the required Dimension E setting 4 Retight...

Page 74: ...S box for Satisfactory Performance and US box for Unsatisfactory Performance Table 19 Dimension E Adjustments Size Adjustments Formed Case Height Dimension E S US Measure the Dimension E against the scale Ensure that the case forming head is resting on the head up latch after pressing the EMERGENCY STOP button Loosen the two yellow quick adjust handles that clamp the forming head assembly to the d...

Page 75: ...dwheel located at the base of the mast See Figure 7 13 The handwheel marked D1 positions the magazine guide the mast assembly and the major flap folders The scale is on the discharge pusher alongside the nearest major flap folder 3 Check the adjustment with an actual case held open with the bottom minor flaps folded The bottom major flaps should pass centrally between the bars of the major flap fo...

Page 76: ...eyor assembly in the tape application section of the WF30T The scale is located on the outfeed end of the machine frame Figure 7 14 D2 Adjustments Check the S box for Satisfactory Performance and US box for Unsatisfactory Performance Table 20 Dimension D Adjustments Size Adjustments Case Width Dimension D S US Measure Dimension D against the scale Adjust first the handwheel located at the base of ...

Page 77: ... the end of the magazine for length adjustment on the machine centerline See Figure 7 17 Check for possible part changes on the minor flap folders before making this adjustment Part changes may be required for case very short in length or square in length and width dimensions C Scale Pointer C Length Adjustment Handwheel Feedbelts Feedbelt Locking Handles A Quick Adjust Handles Magazine Pusher Reg...

Page 78: ...may be necessary to install extensions onto the major flap folding bars to properly control the major flaps Check the S box for Satisfactory Performance and US box for Unsatisfactory Performance Table 21 Dimension C Adjustments Size Adjustments Case Length Dimension C S US Measure Dimension C against the scale Adjust the handwheel provided for length adjustment to the indicated scale setting Check...

Page 79: ...es when finished 3 Pivot the angle guide on the pusher assembly firmly against the cases to ensure that they are tight against the magazine backing plate Check the S box for Satisfactory Performance and US box for Unsatisfactory Performance Table 22 Dimension A Adjustments Size Adjustments Flat Case Width Dimension A S US Loosen the quick adjust handles on the A adjustment assembly Slide the magaz...

Page 80: ...elt Positions When adjusting the feedbelt positions it is important that they be set parallel to the fixed fence side guide for proper feeding Check the S box for Satisfactory Performance and US box for Unsatisfactory Performance Table 23 Dimension H Adjustments Size Adjustments Feedbelt Center Adjustment Dimension H S US Loosen the 4 red quick adjust H handles as shown in Figure 7 21 Adjust the p...

Page 81: ...mance and US box for Unsatisfactory Performance Table 24 Dimension G Adjustment Size Adjustments Case Separator Horizontal Adjustment Dimension G S US Loosen the 2 red quick adjust handles as shown in Figure 7 23 Adjust the position of the case separator while ensuring that it is parallel Retighten quick adjust handles 7 9 Corrugate Thickness Adjustment Dimension F Adjustment of the machine for th...

Page 82: ...ain Control page press the JOG CONTROL button Then press the MACHINE CYCLE JOG button once to close the jaws 4 After adjusting observe the jawplates as a case is injected between them To do so from the HOME position press the MACHINE CYCLE JOG button twice The entry of the case should not cause the jawplates to spring apart noticeably If the jawplates spring by more than 16 1 1 mm the setting is t...

Page 83: ...g fit for a single flat case See Figure 7 26 Figure 7 27 Caliper Adjustment To adjust the caliper setting 1 Loosen the locking handle 2 Move the caliper as appropriate for clearance with the case separator plate of case thickness 1 16 3 Retighten the locking handle Injector Calipers Discharge pusher Adjustment locking handles Caliper clearance case thickness 1 16 ...

Page 84: ...n fully CLOSED is 32 1 1 mm more than the thickness of the flat case Loosen the four socket head capscrews which hold the minor jawplate mounting bracket Move the jawplate the desired amount Retighten the securing screws while maintaining the jawplate s vertical alignment Close guard doors switch ON air and electrical power From the Main Control screen press the JOG CONTROL button Press the MACHIN...

Page 85: ...ers the entire range of possible machine motion For your safety you should never try to bypass the perimeter guarding system or enter the restrictive envelope while the machine is in operation An EMERGENCY STOP button is provided to immediately halt all machine operation by cutting off air supply and electrical power This button should be pushed IN to stop the machine in case of an emergency Preca...

Page 86: ...should not penetrate It may be necessary to raise pins to avoid engaging the wrong flap when the case is opened Engage as many pins as necessary to get a good grip on the case but be aware that having too many pins will make injecting them into the flaps and extracting them more difficult and can also interfere with raising of the forming head after folding the bottom major flaps Engaging too many...

Page 87: ...e top as shown in Figure 8 3 3 Set the pressure regulator on the magazine pusher to the recommended level of between 20 and 35 PSI Figure 8 3 Magazine Pusher Check the S box for Satisfactory Performance and US box for Unsatisfactory Performance Table 26 Magazine Pusher Adjustment Size Adjustments Magazine Pusher Adjustment S US Place some flat cases in the magazine Adjust the pusher arm so that it...

Page 88: ... the Supplementary Manual for further details 8 6 Testing the Size Adjustments After making all of the necessary size adjustments test the machine to check that they are correct Proceed as follows 1 Ensure that the magazine is loaded with cases that are all correctly oriented right way up and that the first case is pushed fully DOWN into the caliper slot against the injector drive bar Refer to Sec...

Page 89: ...t conveyor Discharge Pusher BACK Case taped shut STEP 9 Major Flap Folders OPEN The machine should form the case successfully in a step by step manner If a problem should occur during any one of the above steps analyze the reason for the problem and adjust the machine accordingly If necessary refer to Section 10 3 Machine Sequence Troubleshooting for further assistance 8 When the machine successfu...

Page 90: ...e some other adjustments in Section 7 Case Size Adjustments and Section 9 4 Typical Maintenance Adjustments which do not lend themselves to tabulation They will need to be set as required following the guidelines in the relevant section These adjustments are listed below Table 29 Sensor Adjustment References Adjustment Section Note Case Down Sensor LS 7 Section 8 4 Sensor LS 7 Adjustment Normally ...

Page 91: ...DENTIFICATION OR PRODUCT COUNT ADJUSTMENTS SECTION Refer to Section 7 Case Size Adjustments in the Operation and Service Manual Flat Height B 7 2 Formed Height E 7 3 Formed Width D1 7 4 Formed Width D2 Drivebelts 7 4 Formed Length C 7 5 Flat Length A 7 6 Feedbelts H 7 7 Case Separator G 7 8 Thickness F Jawplates 7 9 1 Thickness F Caliper 7 9 2 Stabilizer Bars Pinblocks 8 2 Magazine Pusher 8 3 Mino...

Page 92: ...ld never try to bypass the perimeter guarding system or enter the restrictive envelope while the machine is in operation An EMERGENCY STOP button is provided to immediately halt all machine operation by cutting off air supply and electrical power This button should be pushed IN to stop the machine in case of an emergency Precautions Do not use flammable or toxic fluids such as gasoline benzene or ...

Page 93: ... machine wear Check the S box for Satisfactory Performance and US box for Unsatisfactory Performance Table 31 Machine Inspection Maintenance and Cleaning Inspection S US Inspect the pneumatic system for leaks Inspect the drain bottle for overflow Inspect for loose fasteners Inspect the belt condition tracking and tension Inspect for irregular noise and signs of wear WARNING The tape knife blade is...

Page 94: ... supply An auto drain vents water automatically from the filter bowl If necessary clean the filter bowl with soapy water Check the S box for Satisfactory Performance and US box for Unsatisfactory Performance Table 32 Cleaning the Machine Maintenance and Cleaning Cleaning S US Remove any corrugated fragment deposits that have accumulated Check the pneumatic filter bowl filter for debris Clean the f...

Page 95: ... cleaner and lubricate the blade guard pad with silicone Weekly Check reducer lubricant level and replenish as required Check conveyor belt condition tracking and tension Monthly Thoroughly clean all adjustment screws sprockets chain and sliding components and then lightly grease See Section 9 8 Lubrication for correct grease Grease sealed guide wheels on mast and discharge pusher Refer to Section...

Page 96: ...se former when downstream demand for cases has been satisfied The sensor must be located at least 4 feet 1 2 meters downstream from the discharge end of the WEXXAR case former for proper operation Make sure there are no false targets in the sensor s sensing range No other adjustments are required 9 4 2 Mechanism Speeds All case former motions are pneumatically driven and their operating speed is c...

Page 97: ...proper function and any excessive wear or damage Inspect magazine pusher cylinder for leaks and proper function Verify that the ON OFF switch for this cylinder is working and that its pressure is correctly regulated as per service manual recommendations Examine magazine pusher bar pivot point at drive carriage for wear Examine drive carriage rollers for damage or wear 9 4 4 Magazine Feedbelts If t...

Page 98: ... Verify the following items on the mast assembly 1 Verify that the mast base gibs are correctly adjusted and show no signs of excessive wear 2 Make sure all collar locking handles are in place 3 Inspect separator cylinder and mast cylinder for damage or leaks 4 Check jaws closed shock absorber for proper function and position 5 Inspect separator guide bushing and rod for wear or damage 6 Inspect s...

Page 99: ...Forming Head Assembly S US Inspect forming head needle bearings and thrust washers for wear Inspect jaw plates for excessive wear or damage Inspect forming head cylinder for wear or damage Check jaws open and forming head up shock absorbers for proper function and position Inspect rod end for wear Inspect LS 2 LS 4 and their cables for damage 9 4 8 Discharge Pusher It is important that the dischar...

Page 100: ...tical on fast running machines 9 4 10 Conveyor Belt Tension Tracking The correct belt tension is factory set on new machines but the tension will decrease when the machine is in service particularly in the first few months and will require regular adjustment to maintain correct case transfer Two adjusting screws are located under each idle pulley They are threaded rods with nuts There is also a lo...

Page 101: ...ition of motors Tach belt speed should be 85 90 FPM Examine pivot point of tilt out deck assembly for any wear 9 4 12 Machine Management System Verify the following items on the discharge conveyor 1 Ensure that all conditions are represented on the beacon 2 Check sensors LS13 14 15 16 12 and their cables for any damage Check the S box for Satisfactory Performance and US box for Unsatisfactory Perf...

Page 102: ... is adjusted by rotating the adjustment screw on the back of the respective sensor Place the target at the correct range and turn the screw until the indicator light comes ON solidly and goes out positively when the target is removed 9 4 15 Flap Folder Assemblies Verify the following items on the flap folder assemblies 1 Inspect all 4 cylinders 2 Examine oilite flange bushings and axles on the maj...

Page 103: ...omes first The rate at which the filter element is contaminated will be greatly affected by the quality of the incoming air If the air is wet or contaminated the filter element will need more frequent replacement 9 5 2 Valve Bank Verify the following item on the valve bank 1 Check valves for leaks and mechanical damage Check the S box for Satisfactory Performance and US box for Unsatisfactory Perf...

Page 104: ...witches are functioning Check the S box for Satisfactory Performance and US box for Unsatisfactory Performance Table 45 Safety Circuit Safety Circuit US S Ensure E STOP and all door switches are functioning 9 6 2 Electrical Enclosure Verify that the electrical enclosure meets the following criteria 1 Check HMI screen for correctness of information and function 2 Examine electrical enclosure for lo...

Page 105: ...hown in Section 9 4 10 Conveyor Belt Tension Tracking Observe the gearmotors that drive the drivebelts for signs of oil leakage if serious leakage occurs replace the gearmotor If all is okay switch the machine ON and observe carefully as it processes a case listening for signs of air leakage or other abnormal noises All mechanical actions should be smooth and free of shock at the end of motion 9 7...

Page 106: ...ect 9 8 Maintenance Parts List 9 8 1 Wear Parts Refer to the attached Supplementary Manual for the Recommended Spare Parts Kit 9 9 Lubrication The main components that require lubrication are Leadscrews Chains and Sprockets Sliding Components Sealed Guide Wheels 9 9 1 Moving Components All adjustment screws chains and sprockets and other sliding components should be thoroughly cleaned and lightly ...

Page 107: ...T 2 Sealed Guide Wheel Lubricant Fuchs Geralyn FMG 387 CAUTION DO NOT use any automotive oils engine oil transmission fluid power steering oil or brake fluid detergent oil or any synthetic oil incompatible with Buna N PVC Polyethylene or nylon Figure 9 4 Discharge Pusher Sealed Guide Wheels Figure 9 5 Mast Assembly Sealed Guide Wheels ...

Page 108: ... enter in through the discharge end while the machine is still powered An EMERGENCY STOP button is provided to immediately halt all machine operation by cutting off air supply and electrical power This button should be pushed IN to stop the machine in case of an emergency Precautions The WF30T Case Former is equipped with safety interlocks Do not attempt to disable the interlocks when repairing th...

Page 109: ...Now operate the appropriate solenoid valve manually If the mechanism moves normally when the valve is actuated manually then the pneumatic system is working and the problem is electrical in nature It may be that the solenoid coil on the valve has failed or it may be that there is a problem with the signal reaching the valve Continue this diagnostic systematic approach until the exact malfunctionin...

Page 110: ...unted with maximum gap to the jawplate Too many pins installed Reduce number of pins Pinblocks not centered on domes Check pinblock alignment Case buckles or tears during injection Injector UP speed too slow Set for optimum injection speed Flap passes between pins jawplate pin sometimes catches the opposite wrong flap Pins too far from jawplate Check pins not bent out Check pinblocks installed wit...

Page 111: ...awplate OPEN position to over square condition to compensate Reset LS 4 to match setting Case does not enter major flap folders smoothly Major flap folders gap too small double wall cases Reposition the secondary straight bar with the holes provided Too many pins pinblocks Reduce number of pins Forming head has difficulty in rising after major flaps have folded Pins mounted in the close to jawplat...

Page 112: ...oting Step No Machine Operation Recommended Checks if Operation Faulty Forming jaws CLOSE Sensor checks LS 1 Head UP ON LS 5 Pusher Back ON LS 8 Major Flap Folders OFF Check solenoid valve V1 Check CYCLE button for faulty operation 1 Magazine feedbelts oscillate Check Solenoid valve V7 2 Injector UP Check LS 2 Jaws CLOSED is ON Check solenoid valve V2 3 Injector DOWN Check solenoid valve V2 4 Form...

Page 113: ...E STOP Check Tape Routing F002 Aux E Stop Activated F007 Box Jam Detected Open Guard Door to Clear Jam F033 Tape Running Push E STOP Check Tape Head F003 Guard Door Open F008 Infeed Conveyor is Empty Fill Infeed Conveyor F034 Tape Finished Push E STOP Check Tape Head F004 Reset Required Control Panel Is Off F009 Air Pressure Low F005 Motor Fault F031 No Tape Applied Push E STOP Check Tape Routing ...

Page 114: ... OFF the electrical power to the machine and then turn it back ON In the unlikely event that these LEDs are still illuminated improperly and you do not have the appropriate PLC interface or training contact WEXXAR s service department Without the appropriate equipment and training to correct this status there is nothing else that you can do After completing the above confirmations 1 Press the RESE...

Page 115: ... time check the LED status in each of the nine MANUAL steps Continuing the MANUAL step sequence after step 9 returns you to step 1 and backup the MANUAL sequence If an LED is not as tabulated stop Look for the possible cause Check for Improperly adjusted sensor or target Incomplete mechanism travel An open or short circuit Allow the air pressure to bleed off before attempting any adjustments or re...

Page 116: ... on solenoid valves Refer to Section 2 6 1 Compressed Air to ensure that an adequate volume of air is supplied Constant leakage from air cylinder rod seals Wear of seal and or piston rod bushing Replace or repair cylinder Seal kits are available for all cylinders except for the disposable type Replace solenoid valve or strip and clean the solenoid air pilot actuated valve assembly Erratic solenoid...

Page 117: ...ose between the machine and the regulator the pressure may have to be adjusted The maximum supply air pressure should be 150 PSI Low Air Pressure Improper supply air line design The minimum inside diameter of the hose between the supply regulator and the machine is for flexible hoses or 1 for steel tubes Auto drain of the filter is not working water accumulated in the cup is not discharged Drain t...

Page 118: ...hine Overheating Too cold Usually caused by high low ambient temperature When ambient temperature is over 60 or below 0 centigrade Table 55 Forming head not moving Problem Possible Cause Solution Compressed air not connected Connect air supply Mechanical Jam Clear mechanical jam Socket loose Tighten socket Open Circuit Cable broken Replace cable Overheating Too cold Usually caused by high low ambi...

Page 119: ...ulated in the cup is not discharged Drain water in the filter cup and fix the auto drain valve or replace the filter cup Water Condensation Too much water in the air supply Dry the air before it enters the machine 10 6 1 Other Typical Pneumatic Issues Forming head and or jaw too fast 1 Air pressure regulators set too high Air pressure at machine s main regulator should be 90 PSI Air pressure at ma...

Page 120: ...FF OFF OFF OFF OFF OFF OFF ON OFF REMOTE DEMAND 1 LS 11 I 0 11 OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF AIR PRESSURE PS 1 I 0 1 ON ON ON ON ON ON ON ON ON ON LOW MAGAZINE 3 LS 14 I 0 14 ON ON ON ON ON ON ON ON ON ON EMPTY MAGAZINE LS 13 I 0 13 ON ON ON ON ON ON ON ON ON ON NO TAPE MONITOR 3 LS 12 I 0 12 OFF OFF OFF OFF OFF OFF OFF OFF INTERMITTENT OFF LOW TAPE 3 LS 16 I 0 16 OFF OFF OFF OFF OFF OFF...

Page 121: ...FF OFF INJECTOR UP V2 O 0 2 OFF OFF ON OFF OFF OFF OFF OFF OFF OFF HEAD SEPARATOR DOWN V3 O 0 8 OFF OFF OFF OFF OFF ON ON OFF OFF OFF MINORS UP V4 O 0 4 OFF OFF OFF OFF OFF ON OFF OFF OFF OFF OFF MAJORS TURNED FOLDED V5 O 0 5 OFF OFF OFF OFF OFF OFF ON ON ON OFF PUSHER OUT V6 O 0 6 OFF OFF OFF OFF OFF OFF OFF OFF ON OFF MAGAZINE 1 FEEDBELTS V11 O 0 7 OFF STEADY CYCLING SECOND ON SECOND OFF ON OFF ...

Page 122: ...le cylinder is used to drive the separator motions Repair kits to replace all wear components in this cylinder are available When ordering repair kits ensure that the correct cylinder is specified Band type Rodless A rodless cylinder is used to drive the magazine pusher mechanism This cylinder can be overhauled to replace all wear components Non repairable Type Non repairable cylinders are used to...

Page 123: ...e attached to each of the four pivot links Each pivot link houses two bearings one at each end 2 Remove and rebuild the links one at a time The lower links will slide down off the stationary pins To remove the upper links a Remove the clevis pin from the forming head cylinder clevis and swing the cylinder out of the way b Remove the cast aluminum drive bar from the stationary pins c It is now poss...

Page 124: ...ken the belt tensioning nuts to the fully BACK position This will permit belt removal by starting at the idle pulley end and lifting the belt off upwards and back 3 Replace with a new belt 4 Make marks 25 apart on the belt before any load is applied 5 Tension the belt by tightening the tensioning screws equally to achieve a measurement of 25 between the marks 1 percent stretch 6 Run the belts to e...

Page 125: ...14 AWG 4 wire rated to 600V or equivalent Air Requirement 0 90 ft3 per case at 90 PSI 6 bar 27 SCFM Pneumatic Hose Gauge Minimum inside diameter of 3 4 for flexible tubes or 1 for steel tubes Speed Up to 30 CPM depending on case size and case quality Available high speed mode to 30 CPM Tape System DEKKA Model WEX 22 tape applicator head Other makes optional Approx Weight 1 300 lbs 590 kg Case Styl...

Page 126: ... Data Sheet Trainee prerequisites Knowledge of basic mechanical operations and reading skills Classroom time 30 minutes Hands on training 2 hours Total training hours 2 5 hours Optimum number of trainees 10 in classroom training sessions 2 to 1 in hands on training sessions ...

Page 127: ...trainees Refer to Section 3 1 Major Components and Section 4 1 Sequence of Operations for reference 2 Controls Description 5 minutes This lesson familiarizes trainees with the controls of the WF30T It is ideally carried out in a hands on tutorial where the controls of the machine may be demonstrated directly However a classroom presentation is not a bad option if there are a large number of traine...

Page 128: ... cases of different sizes A hands on tutorial is best Refer to Section 7 Case Size Adjustments 7 Clearing Jams 3 minutes This lesson shows trainees how to respond to a case jam A hands on tutorial is best Refer to Section 6 4 Clearing a Case Jam 8 Shutdown 5 minutes This lesson enlists the steps involved in shutting down the machine A hands on tutorial is best Refer to Section 6 5 Shutdown 9 Maint...

Page 129: ...Dimension B Adjustments 7 2 19 Dimension E Adjustments 7 3 20 Dimension D Adjustments 7 4 21 Dimension C Adjustments 7 5 22 Dimension A Adjustments 7 6 23 Dimension H Adjustments 7 7 24 Dimension G Adjustment 7 8 25 Dimension F Adjustments 7 9 2 26 Magazine Pusher Adjustment 8 3 31 Machine Inspection 9 2 1 32 Cleaning 9 2 2 33 Magazine Pusher Maintenance 9 4 3 34 Feedbelt Maintenance 9 4 4 35 Inje...

Page 130: ...ou are to perform and the standards you must demonstrate to successfully complete the performance assessment 5 Record the start and stop times 6 Check each block of the performance checklist as the trainee satisfactorily performs the step 7 Stop the trainee any time that a step is scored as unsatisfactory and at the end the evaluation 8 Sign and date beside each checklist as it is completed 9 Have...

Page 131: ...t against failure or defective workmanship Components purchased from other manufacturers by WEXXAR are warranted for the duration of the manufacturer s warranty This warranty does not extend to parts that may presumably be expected to wear out during the warranty period Damage caused by misuse improper maintenance negligence or accident shall void the warranty on the equipment The warranty provide...

Page 132: ...nue longer than programmed and the machine shuts down on a Tape Running logic test The Red and Amber beacons flash alternately until the machine is RESET 3 Low Tape Monitor When the tape roll has been depleted to a preset low level the sensor activates the flashing Amber beacon indicating that the tape roll will have to be replaced soon The machine logic then measures the tape length dispensed and...

Page 133: ... be completed all machine mechanisms will then stop at their HOME positions A steady ON beacon signal takes precedence over a flashing signal When a machine shutdown condition is corrected all other potential shutdown conditions should be checked and corrected before restarting the machine Figure 14 1 Beacon Lamp Status Indicators NOTE Multiple conditions can occur simultaneously but not all can b...

Page 134: ...Reset 5 27 Servo Settings Start 5 44 Servo Settings Stop 5 44 Setup 5 33 Start 5 29 Stop 5 29 6 54 C Caliper 3 12 Case Injection 4 18 Case Length 7 64 Case Measurement Dimensions 5 31 Case Measuring 7 56 7 68 Case Opening 4 18 Case Sealing 4 18 Case Separation 4 17 Case Separator 3 12 Case Size Range 7 56 Case Supply 4 17 Case Width 7 62 Cleaning 9 81 Clearing Jams 6 52 Clutch Bearing 10 110 Colla...

Page 135: ...6 50 Jog Step Sequence 10 107 10 108 L LED Status Tables 10 107 Left Hand Cases 7 56 Leveling 2 7 Location 2 7 Low Pressure Switch 4 26 Lubricants 1 4 9 94 Lubrication 9 82 9 93 M Machine Management 14 119 Machine Management System 9 88 Magazine 3 14 Magazine Feedbelts 3 12 9 84 Magazine Guide Rail 3 14 Magazine Loading 6 51 Magazine Management 4 19 4 20 Magazine Pusher 3 14 8 74 9 84 Main Control...

Page 136: ...3 Electrical 1 3 Guard Doors 1 3 Interlock Switches 1 4 Safety Circuit 9 91 Safety Considerations 1 2 Safety Lock outs 1 3 Safety Standards 1 2 Screens Box Settings 5 30 5 31 High and Low Speed 5 42 Main Control 5 29 Servo Settings 5 42 Sealed Guide Wheels 9 93 Sensors 4 19 8 77 Adhesive System 4 21 Adjustments 8 77 Inductive 3 13 4 19 9 89 Infrared 3 13 LS 7 8 75 Magazine Management 4 19 4 20 Pro...

Page 137: ...WF30T Case Former Appendix A MSDS Geralyn FMG 387 124 Wear Parts 9 93 APPENDIX A Material Safety Data Sheets Fuchs Lubricants Geralyn FMG 387 ...

Page 138: ...WF30T Case Former Appendix A MSDS Geralyn FMG 387 125 FUCHS LUBRICANTS CANADA LTD PACIFIC DIVISION Material Safety Data Sheet WHMIS Not controlled ...

Page 139: ...WF30T Case Former Appendix A MSDS Geralyn FMG 387 126 ...

Page 140: ...WF30T Case Former Appendix A MSDS Geralyn FMG 387 127 ...

Page 141: ...WF30T Case Former Appendix A MSDS Geralyn FMG 387 128 ...

Page 142: ...WF30T Case Former Appendix A MSDS Geralyn FMG 387 129 ...

Page 143: ...WF30T Case Former Appendix A MSDS Geralyn FMG 387 130 ...

Page 144: ...WF30T Case Former Appendix A MSDS Geralyn FMG 387 131 ...

Page 145: ...WF30T Case Former Appendix B MSDS Keystone Nevastane HT 2 132 APPENDIX B Material Safety Data Sheets Keystone Lubricants Nevastane HT 2 ...

Page 146: ...WF30T Case Former Appendix B MSDS Keystone Nevastane HT 2 133 ...

Page 147: ...WF30T Case Former Appendix B MSDS Keystone Nevastane HT 2 134 ...

Page 148: ...WF30T Case Former Appendix B MSDS Keystone Nevastane HT 2 135 ...

Page 149: ...WF30T Case Former Appendix B MSDS Keystone Nevastane HT 2 136 ...

Page 150: ...WF30T Case Former Appendix B MSDS Keystone Nevastane HT 2 137 ...

Page 151: ...OPERATION SERVICE MANUAL 65 35 1 Effective June 17 2009 BEL 290 FULLY AUTOMATIC TOP AND BOTTOM CASE TAPE SEALER Wexxar Packaging Inc Phone 604 930 9300 Fax 604 930 9368 E mail sales wexxar com ...

Page 152: ...erated by qualified personnel only 0 2 9 Standard Specifications Length Width Height Case Size Range Minimum 6 152 mm 5 127 mm 5 127 mm Maximum 22 559 mm 18 457 mm 19 483 mm Machine Dimensions 79 2008 mm 39 987 mm 62 1575 mm In Outfeed Height Frame 22 3 563 mm With adjustable leg extensions foot pad Minimum Maximum 24 5 622 mm 32 813 mm Speed Up to 32 cases min Shipping Weight Approx 1 100 lbs 500...

Page 153: ...ompression 10 TOP SKI FLAP WIDTH ADJUSTMENT 11 STARTING THE MACHINE 12 COMPRESSED AIR 12 ELECTRICAL SWITCHING 13 CONTROLS 14 CONTROLS OVERVIEW 14 CONTROLS DESCRIPTION 15 FEEDING CASES INTO THE MACHINE 26 STOP GATE OPTION 26 SERVICE AND MAINTENANCE PROCEDURES 27 EQUIPMENT SAFETY 27 PREVENTIVE MAINTENANCE 28 Weekly Inspection 30 Monthly Inspection 30 SIDE BELT CONVEYOR SYSTEM 31 Chain Drive 32 Gear ...

Page 154: ...the appropriate outfeed height 4 Position the machine where it is to be used LEVELING THE MACHINE The machine should be level to avoid frame stress and ensure optimum performance An adjustable height footpad kit is included as standard equipment and can be used to level the machine on an uneven floor The machine should be anchored to adjoining equipment or the floor to prevent any movement of the ...

Page 155: ...ic The BEL 290 is equipped with single phase 110 120 VAC electrics to NEMA 12 specifications A 1 2 horsepower TEFC motor that draws eight amps powers the drive system A minimum AWG 14 gauge power extension cord with standard three pin connection must be used to connect the machine to the power source If any electrical connections are needed to install the machine they must be handled by a qualifie...

Page 156: ... run a particular case size 1 Case width adjustment D Use the hand crank on the side of the bottom frame to move side belt conveyors in and out to fit the width of the case 2 Case height adjustment E Use the side hand crank on the top guarding frame to vertically adjust the machine head with the top flap folders and tape head to match the height of the closed case D D E 120 093 In practice it is b...

Page 157: ...O M A T I C C A S E T A P E S E A L E R 7 65 35 1 06 17 09 CASE HEIGHT ADJUSTMENT Case Dimension E Adjustment Use the case height crank and scale on the side of the arch to adjust the case height to Dimension E CASE HEIGHT SCALE E ...

Page 158: ...ve method to using the width scale is first to move the side belt conveyors apart until wider than the case to be run Then adjust the conveyors back in until they lightly contact the case sides Remove the case through the machine infeed and wind the belts in by a further one half turn This usually moves the conveyor to the correct position for a good grip on the case Note Depending on case fill we...

Page 159: ...ds If necessary loosen the bolts that lock the top major flap folding rods in position and adjust their position so that they capture the top case flaps and fold them down ahead of the top tape head as the case passes under them The rods will need to be moved inward toward each other for narrow cases and outward for wide ones ...

Page 160: ...ion D3 Case Side Compression Adjust the side compression rollers to control the tendency of the upper sides of the case to expand due to incorrect top flap folding and perhaps case overfilling The side compression rollers should minimize the gap between the top major flaps while they are being taped ...

Page 161: ...e position of the ski to keep control of the minor flaps To run most case widths close to the machine s average width capabilities the ski should be set at the midpoint on its mounting slot With cases that are close to the maximum machine width capability or with larger than normal minor flaps the ski should be adjusted back away from the machine infeed so that the rear minor flap does not hit the...

Page 162: ...activated guard doors are opened or when the main power is switched OFF To carry out service or repair work safely on the machine the manual air ON OFF valve is located on all WEXXAR machines upstream of the filter regulator unit Padlock this valve in the OFF position for absolute safety during service work Always follow local lock out tag out regulations Always exercise caution when switching the...

Page 163: ...r startup cycles and be ready for machine operation The lockable MAIN DISCONNECT switch should be OFF and locked before service work is attempted outside of the control enclosure Before performing service work inside of the control enclosure disconnect all electrical power to the machine either by unplugging the supply cord or switching OFF a separate customer supplied disconnect The main supply v...

Page 164: ...l machine operations The screen interface provides operator control of the machine through software pushbuttons displayed on the screen It also provides instructions related to machine operation This section lists the standard controls on a BEL 290 Actual control functions may vary depending on options installed on your machine Pay special attention to the location of the EMERGENCY STOP button the...

Page 165: ...e EMERGENCY STOP button immediately cuts off electrical and air supply to the machine and halts the conveyor belts regardless of whether a case is positioned in the forming process when the button is pushed IN Note that the kicker retracts to its HOME position if it is not already there Power is cut from the main air solenoid valve and all mechanisms Restarting the machine after an EMERGENCY STOP ...

Page 166: ...atus messages are shown green in the Main Control screen in the Machine Alarm display Machine fault messages are shown on this display in red They identify serious problems with the machine Amber remedy messages and cautionary messages of impending faults are scrolled in the Warning Message display immediately below the machine status messages In the bottom left center of the Main Control screen i...

Page 167: ...le 8 TOTAL NUMBER OF CASES Button and Display The TOTAL NUMBER OF CASES display indicates the total number of cases sealed This counter can be reset to 0 To reset this value press the touch sensitive area with the blue numerals When this button is touched a confirmation message will appear To reset the case counter to 0 touch YES Otherwise touch NO 9 ACTUAL CPM Display The ACTUAL CPM display shows...

Page 168: ...Note that the SELECTED CPM display does not appear if the optional stop gate function is not included or not in use on your machine 11 SETUP Button To change any of the machine control settings or to put the machine into DRY CYCLE the machine operation for the purpose of troubleshooting press the SETUP button in the bottom right hand corner of the Main Control screen The SETUP button disappears fr...

Page 169: ...can assist the operator when troubleshooting or making machine adjustments Alarm History Screen Touch the CLEAR button in the bottom center of the screen to clear the Alarm History list Touch the blank field in the Password window to bring up an Alphanumeric Keypad window Type the required password Then touch the ENT key If you enter an invalid password an error message will display Touch the PREV...

Page 170: ...able Logic Controller inputs and outputs Touch the TROUBLESHOOTING button to be taken to the Troubleshooting screen Troubleshooting Screen 15 Troubleshooting Screen In the center of the Troubleshooting screen are the PLC INPUTS and PLC OUTPUTS buttons 16 SERVICE Button The SERVICE button is located in the upper right hand corner of the screen Touch the SERVICE button to bring up the Service screen...

Page 171: ...tion press the DRY CYCLE ON OFF button The button will now read DRY CYCLE OFF When the machine is in DRY CYCLE operation a small indicator appears at the bottom of the screen displaying the text DRY CYCLE ACTIVE To exit DRY CYCLE operation press the DRY CYCLE ON button so that the button displays the text DRY CYCLE OFF 19 MAIN CONTROL Button This button is located to the bottom left of the touchsc...

Page 172: ... some of these parameter options will not be available on machines which do not come equipped with a stop gate or remote demand sensor Parameters Screen 22 KICKER DOWN TIME Button To change the KICKER DOWN TIME touch the blue numerals of this value An Alphanumeric Keypad window will appear Enter the new value and then touch ENTER This will enter the new KICKER DOWN TIME value The acceptable range ...

Page 173: ...TER This will enter the new STOP GATE DOWN TIME value The acceptable range for this value is 2 20 hundredths of a second 26 REMOTE DEMAND TIME Button The remote demand time sets the delay required to ignore cases passing by the sensor in normal transit as opposed to those stationary in front of it due to a downstream backup indicating the need to stop further cases from being processed through the...

Page 174: ...tors for 24 machine functions If one of the 24 machine components is not functioning the corresponding indicator will be flashing on and off Note that the function indicators are not buttons They are not touch sensitive Touch the PREVIOUS button in the bottom right hand corner of the screen to return to the Troubleshooting screen or touch the MAIN CONTROL button in the bottom left hand corner of t...

Page 175: ...trols a PLC output directly To test these functions stop the machine and remove any unformed cases from the magazine Then touch each button When a button is touched it will illuminate and that machine component will function If it does not function inspect and repair the component Touch the PREVIOUS button in the bottom right hand corner of the PLC Outputs screen to return to the Troubleshooting s...

Page 176: ...is the preferred method of feeding cases to the BEL 250 although gravity or manual feed may also be used For powered conveyor infeed a speed of 60 FPM or less is recommended STOP GATE OPTION The BEL 290 can be equipped with an optional timed stop gate that separates the cases as they enter into the machine Stop gate shown in the up or closed position ...

Page 177: ...s the perimeter guarding system or enter the restrictive envelope while the machine is in operation The EMERGENCY STOP button immediately halts all machine operation by cutting off air supply and electrical power This button should be pushed IN to stop the machine in case of an emergency Precautions Do not use flammable or toxic fluids such as gasoline benzene or ether to clean the equipment Do no...

Page 178: ...the tensioner on the side which the belt moves towards Watch for signs of improper belt tensioning such as the belts slipping when transporting a heavy case 3 Gear reducers Observe the gear reducers for signs of oil leakage If oil leakage occurs check the oil level by removing the oil level plug to ensure that the correct oil quantity is present Top up if necessary 4 Filter bowl Regularly check th...

Page 179: ...ntain the oil at the proper level Inspect the pneumatic filter bowl for debris Clean the bowl if necessary Drain the water overflow bottle Inspect and tighten all machine fasteners Inspect the kicker for bolt tightness listen for banging sounds Inspect the stop gate for bolt tightness listen for banging sounds Inspect for machine wear listen for any irregular noise Cleaning The machine inspection ...

Page 180: ...oughly cleaned and lightly greased If the environment is extremely dirty or if some sticking is experienced a shorter interval is recommended Remove only one guide tube at a time per acme nut to avoid rotation of the nut This will prevent misalignment of the drivebelts NOTE The gear reducer lubricant should be changed after the initial 1 500 hours of operation and after every 5 000 subsequent hour...

Page 181: ...inished appearance It occurs due to both conveyor side belts being driven by a single motor and reduction gear that inherently synchronizes belt speeds Chain tension is maintained during case width adjustments through a self compensating serpentine configuration Side belt Conveyor System Drive Chain Idler Sprocket Side belt Conveyor Drive Chain Idler Sprocket Loosen mounting bolt under drive housi...

Page 182: ...d prior to restarting the machine The optional BEL 250 SB55 Spare Parts Maintenance Kit 70 011 contains all of the parts necessary for maintaining the conveyor system Contact the factory or your local Belcor distributor for price availability etc Gear Reducer Gear reducers should be inspected regularly for evidence of oil leakage excessive noise or vibration in order to ensure maximum performance ...

Page 183: ...ing the top cover assemblies from each side unit We recommend replacing both belts at the same time The belt replacement procedure for each side is as follows 1 Remove the case infeed guide plate as shown 2 Release the belt tension with top and bottom tension adjusting screws and remove the top adjusting screw 3 Remove the idle pulley top plate ...

Page 184: ... Reset the belt tension by adjusting the top an bottom tensioning screws to both tension and position the belt on the idle pulley so that it is running true and not trying to ride up or down Set the belt tension just enough to prevent the belts from slipping during use excessive tension will cause premature belt and bearing wear Replace the case infeed guide plates For detailed information please ...

Page 185: ...that needs quality control The fluted construction of corrugated board can be impaired by various factors in the corrugated case manufacturing process Points to watch for a That the flutes have not been crushed overall causing the case to have a soft and limp feeling This can create poor crispness during machining and also not give your product the protection it requires b Selective bands of crush...

Page 186: ... cans or bottle type products ensure that the belts are set to grip lightly but firmly on the case sides Excessive side pressure can cause round objects to roll over center and push the case out of square Problem Depressed Crushed Band on the Lower Case Check for excessive side pressure Problem Rubber Dust Being Shed by the Belts Ensure that the belt tensioning and tracking adjustments are correct...

Page 187: ...nd prior to clearing the jam Open the belts and raise the head Remove jammed case and debris Check for jam causes The belts set too tight causing machine overloading The product is overfilled or inconsistent causing intermittent jams The top flap folding is not set correctly The flaps subsequently hit the ski or tape head mechanism The tape head is adjusted too low ...

Page 188: ...lling tension is smooth and not too stiff because a snap back caused by excessively stretched tape can cause a jagged cut off and tape pieces to stick to blade Be sure that the knife is adjusted to a high enough position to contact the tape fully during cutting Inspect the cut off blade for wear or damage The blades must be very sharp to work well The points are easily damaged if contacted by any ...

Page 189: ...Bottom Head This can be caused by a lack of static on the bottom wipe down roller Inspect for contamination or extra tape wound around the roller Dust the roller surfaces with talcum powder to increase static on the roller Ensure that the tape holder or finger is set correctly See the manual for appropriate tape heads ...

Page 190: ...h ensures that cases enter the automatic sealing machines in a timed manner in order to prevent jams caused by more than one case being in process at one time This option is normally used when an accumulation or backlog of cases is expected on the infeed conveyor When cases are hand packed it is not normal to need a stop gate because they are fed one at a time to the sealer The stop gate is in the...

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