3M 39800 User Manual

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3M-Matic 800rf Type 39800 Automatic Random Case Sealer with AccuGlide
II Taping Heads
Service Manual
Printed in U.S.A.
3M Center, Building 220-8W-01 3M-Matic and AccuGlide are trademarks of 3M, All rights reserved. St. Paul, MN 55144-1000 St. Paul, MN 55144-1000 78-8114-0965-1 Rev. B
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Replacement Parts and Service Information
To Our Customers:
This is the 3M-Matic/AccuGlide/Scotch brand equipment you ordered.
It has been set up and tested in the factory with Scotch brand tapes. If technical assistance or replacement parts are needed, call or Fax the appropriate number listed below.
Technical Assistance
3M-Match Helpline 1-800/328 1390. Please provide the customer support
coordinator with the machine number, machine type/model and serial number. If you have a technical question that does not require an immediate response, you may Fax it to 715/381 0248.
Replacement Parts
Order parts by part number, part description and quantity required. Also include machine name, number and type. A parts order form is provided at the end of Section 7 of this manual, Illustrated Parts Breakdown.
3M/Tape Dispenser Parts 241 Venture Drive 1-800/344 9883 Amery, WI 54001-1325 FAX# 715/268 8153
Minimum billing on parts orders will be $25.00. Replacement part prices available on request.
Note: Outside the U.S., contact the local 3M subsidiary for parts ordering information.
$10.00 restocking charge per invoice on returned parts.
3
3M Packaging Systems Division
3M Center, Building 220-8W-01 St. Paul, MN 55144-1000
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Replacement Parts and Service Information
To Our Customers:
This is the 3M-Matic/AccuGlide/Scotch brand equipment you ordered.
It has been set up and tested in the factory with Scotch brand tapes. If any problems occur when operating this equipment, and you desire a ser­vice call, or phone consultation, call, write, or Fax the appropriate number listed below.
SERVICE AND PARTS AVAILABLE DIRECT FROM:
Order parts by part number, part description and quantity required. Also include machine name, number and type.
3
3M Packaging Systems Division
3M Center, Building 220-8W-01 St. Paul, MN 55144-1000
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3M-Matic 800rf Case Sealer Revision History
3M-Matic800rf Service Manual
Revision History
The original issue of this manual and subsequent revisions are identified as follows:
Issue date (Rev. A): 12/98, (Rev. B): 9/99
Revision B revised pages include:
Page Date
Title Page 9/99 Revision History 9/99 vi 9/99 5-3 through 5-8 9/99 5-11, 5-12 9/99 5-21 9/99 7-5 9/99 7-8 through 7-11 9/99 7-18 through 7-20 9/99 7-40 9/99 7-42 9/99 7-48 9/99 7-54 9/99 7-56 through 7-58 9/99 7-61 9/99 7-65 9/99 A-i 9/99 A-13 through A-42 9/99
Copyright 1999, 3M IPC. All rights reserved. i
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Revision History 3M-Matic 800rf Case Sealer
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ii Copyright 1999, 3M IPC. All rights reserved.
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3M-Matic 800rf Case Sealer Table of Contents
Section 1. Description and Specifications
1-1. Intended Use ............................................................................................................................................. 1-1
1-2. Description ............................................................................................................................................... 1-2
1-3. Specifications ........................................................................................................................................... 1-3
1-4. Case Sealing Rate Approximation Formula .............................................................................................1-4
1-5. Machine Dimensions ................................................................................................................................1-5
Section 2. Installation
2-1. General ..................................................................................................................................................... 2-1
2-2. Unpacking................................................................................................................................................. 2-2
2-3. Setup Procedure ........................................................................................................................................ 2-3
2-3-1. Case Sealer Bed Height ............................................................................................................... 2-3
2-3-2. Rear Emergency Stop Switch Installation ................................................................................... 2-3
2-3-3. Warning Beacon Installation ....................................................................................................... 2-4
2-3-4. Pneumatic Connection................................................................................................................. 2-4
2-3-5. Air Pressure Indicator.................................................................................................................. 2-5
2-3-6. Air Pressure Regulators ............................................................................................................... 2-5
2-3-7. Electrical Connection .................................................................................................................. 2-6
2-4. Tape Loading ............................................................................................................................................2-8
2-4-1. Top Tape Head Loading ..............................................................................................................2-9
2-4-2. Bottom Tape Head Loading.......................................................................................................2-10
2-5. Tape Drum Friction Brake...................................................................................................................... 2-11
2-6. Checkout Inspection (to be performed by an authorized 3M Service Technician) ................................ 2-11
2-6-1. Static Tests ................................................................................................................................. 2-11
2-6-2. Programmable Controller Inputs and Outputs...........................................................................2-15
2-6-3. Dynamic Tests ...........................................................................................................................2-19
2-7. Placing 800rf Case Sealer in Production Line ....................................................................................... 2-20
2-8. Special Setup Procedure .........................................................................................................................2-21
2-8-1. Relocating Pneumatic and Electrical Control Panels ................................................................2-21
Section 3. Adjustments
3-1. Case Sealer Bed Height ............................................................................................................................3-1
3-2. Pneumatic Device Factory Set Points ...................................................................................................... 3-2
3-3. Main Air Pressure Regulator ....................................................................................................................3-4
3-4. Box Centering Pressure Regulator ........................................................................................................... 3-4
3-5. Side Belt Pressure Regulator .................................................................................................................... 3-5
3-6. Side Belts Closure Drive Chain................................................................................................................ 3-5
3-7. Side Belts In/Out Rates ............................................................................................................................ 3-6
3-8. Side Belt Inner Limit ................................................................................................................................3-7
3-9. Side Belt Tension...................................................................................................................................... 3-8
3-10. Motor Drive Belts, Upper and Lower ...................................................................................................... 3-9
3-11. Drive Chain ............................................................................................................................................ 3-10
3-12. Safety Door Interlock ............................................................................................................................. 3-10
3-13. Flap Folder Arm and Flap Folder Flow Controls - Speed Controls ....................................................... 3-11
3-14. Flap Folder Arm Reed Switch ................................................................................................................ 3-12
3-15. Cylinder Cushion Setting ....................................................................................................................... 3-13
3-16. Paddle Pressure Regulator ...................................................................................................................... 3-13
Copyright 1999, 3M IPC. All rights reserved. iii
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Table of Contents 3M-Matic 800rf Case Sealer
3-17. Counter-Balance Pressure Regulator...................................................................................................... 3-14
3-18. Case Top Sensitivity ............................................................................................................................... 3-14
3-19. Fork Cylinder Flow Controls - Speed Controls...................................................................................... 3-15
3-20. Infeed Box Stop-Gate Flow Control - Speed Control ............................................................................ 3-16
3-21. Box Centering Rails In/Out Rates .......................................................................................................... 3-17
3-22. Upper Head Assembly Down/Up Rates ................................................................................................. 3-18
3-23. Top Flap Compression Rollers ...............................................................................................................3-19
3-24. Tape Web Alignment .............................................................................................................................. 3-19
3-25. Tape Drum Friction Brake...................................................................................................................... 3-20
3-26. Tape Applying Mechanism Spring ......................................................................................................... 3-20
3-27. One-Way Tension Roller ........................................................................................................................ 3-21
3-28. Low Air Pressure Switch ........................................................................................................................3-22
3-29. Overload Circuit Breaker ....................................................................................................................... 3-23
3-30. Head Travel Limit Switch ...................................................................................................................... 3-23
Section 4. Disassembly/Reassembly
4-1. General ..................................................................................................................................................... 4-1
4-2. Format....................................................................................................................................................... 4-1
4-3. Side Drive Belt Assembly ........................................................................................................................ 4-2
4-4. Side Drive Belt ......................................................................................................................................... 4-3
4-5. Motor Drive Belts, Upper and Lower ...................................................................................................... 4-4
4-6. Case Sealer Bed Plates ............................................................................................................................. 4-6
4-7. Fork Cylinder............................................................................................................................................ 4-7
4-8. Side Drive Belts Cylinder......................................................................................................................... 4-7
4-9. Flap Folder Cylinder ................................................................................................................................ 4-8
4-10. Flap Folder Arm Cylinder ........................................................................................................................ 4-8
4-11. Knife Replacement, Upper Taping Head ..................................................................................................4-9
4-12. Knife Replacement, Lower Taping Head ............................................................................................... 4-10
4-13. Belt Drive Pulley Assembly Ribbed Rings ............................................................................................ 4-10
4-14. Infeed Rollers ......................................................................................................................................... 4-12
4-15. Overload Circuit Breaker ....................................................................................................................... 4-14
Section 5. Theory of Operation
5-1. General ..................................................................................................................................................... 5-1
5-2. Operation Summary.................................................................................................................................. 5-1
5-2-1. Random Mode ............................................................................................................................. 5-1
5-2-2. Fixed Mode ................................................................................................................................. 5-2
5-2-3. Bypass Mode ............................................................................................................................... 5-2
5-3. Sequence Tables ....................................................................................................................................... 5-2
5-4. Electrical System ....................................................................................................................................5-14
5-4-1. Power Distribution ....................................................................................................................5-14
5-4-2. Special Circuits/Components ....................................................................................................5-14
5-4-3. Electrical Schematic ..................................................................................................................5-16
5-5. Pneumatic System .................................................................................................................................. 5-20
Pneumatic Diagram ................................................................................................................... 5-21
iv Copyright 1999, 3M IPC. All rights reserved.
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3M-Matic 800rf Case Sealer Table of Contents
Section 6. Troubleshooting
6-1. General ..................................................................................................................................................... 6-1
6-2. Troubleshooting Guide ............................................................................................................................. 6-1
6-3. Pneumatic Component Testing .................................................................................................................6-6
6-4. Electrical Circuit Fault Conditions ........................................................................................................... 6-8
Section 7. Illustrated Parts Breakdown
7-1. How to Order Replacement Parts .............................................................................................................7-1
7-2. Spare Parts ................................................................................................................................................7-1
7-3. Suggested Spare Parts .............................................................................................................................. 7-1
7-4. Illustrations and Parts Lists ...................................................................................................................... 7-2
Figure 7-1. 800rf Case Sealer Breakdown .............................................................................................. 7-2
Figure 7-2. Conveyor Frame ................................................................................................................... 7-4
Figure 7-3. Conveyor Center Bed and Fork ............................................................................................ 7-8
Figure 7-4. Conveyor Bed Rollers......................................................................................................... 7-10
Figure 7-5. Side Belt Centering .............................................................................................................7-12
Figure 7-6. Column Assembly ...............................................................................................................7-16
Figure 7-7. Flap Folder Assembly ......................................................................................................... 7-18
Figure 7-8. Paddle Assembly................................................................................................................. 7-22
Figure 7-9. Side Belt Rail Assembly ..................................................................................................... 7-24
Figure 7-10. Head Cylinder Assembly .................................................................................................. 7-26
Figure 7-11. Upper Tape Head Mount................................................................................................... 7-28
Figure 7-12. Upper Tape Drum Bracket Assembly ............................................................................... 7-30
Figure 7-13. Side Belt and Drive Assemblies ....................................................................................... 7-32
Figure 7-14. Side Belt Drive Pulleys (Detail) ....................................................................................... 7-36
Figure 7-15. Upper Head Conduit Assembly ........................................................................................ 7-38
Figure 7-16. Electrical Control Panel ....................................................................................................7-40
Figure 7-17. Electrical Control Panel (Detail) ...................................................................................... 7-44
Figure 7-18. Pneumatic Control Panel .................................................................................................. 7-46
Figure 7-19. Pneumatic Components, #1 .............................................................................................. 7-48
Figure 7-20. Pneumatic Components, #2 .............................................................................................. 7-50
Figure 7-21. Pneumatic Components, #3 .............................................................................................. 7-52
Figure 7-22. Sliding Door Assembly .....................................................................................................7-56
Figure 7-23. Infeed Conveyor Frame .................................................................................................... 7-60
Figure 7-24. Infeed Conveyor Drive Assembly ..................................................................................... 7-64
Figure 7-25. Infeed Conveyor Centering Assembly .............................................................................. 7-66
Figure 7-26. Taping Head Assemblies - AccuGlide
Figure 7-27. Frame Assembly for Upper Head ..................................................................................... 7-72
Figure 7-28. Applying Assembly for Upper and Lower Heads ............................................................. 7-74
Figure 7-29. Buffing Assembly for Upper Head ................................................................................... 7-76
Figure 7-30. Link Assembly for Upper and Lower Heads ....................................................................7-78
Figure 7-31. Knife Assembly for Upper and Lower Heads................................................................... 7-80
Figure 7-32. Tape Drum and Bracket for Upper and Lower Heads ...................................................... 7-82
Figure 7-33. Frame Assembly for Lower Head ..................................................................................... 7-84
Figure 7-34. Buffing Assembly for Lower Head ...................................................................................7-86
II STD 2-Inch ................................................... 7-70
Copyright 1999, 3M IPC. All rights reserved. v
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Table of Contents 3M-Matic 800rf Case Sealer
Section 8. Preventative Maintenance
8-1. General ..................................................................................................................................................... 8-1
8-1-1. Maintenance ................................................................................................................................ 8-1
8-1-2. Tool Kit ....................................................................................................................................... 8-1
8-2. Cleaning.................................................................................................................................................... 8-1
8-3. Lubrication ............................................................................................................................................... 8-2
8-3-1. Taping Heads ............................................................................................................................... 8-2
8-3-2. Main Assembly and Infeed Assembly ......................................................................................... 8-2
8-4. Maintenance Schedule.............................................................................................................................. 8-4
8-4-1. Taping Heads ............................................................................................................................... 8-4
8-4-2. Infeed Assembly .......................................................................................................................... 8-4
8-4-3. Main Assembly ............................................................................................................................ 8-5
Appendix A. PLC Addendum
A-1. SLC 500 Controller Description ............................................................................................................. A-1
A-2. SLC 500 Specifications ........................................................................................................................... A-1
A-3. Programming ........................................................................................................................................... A-4
A-4. Troubleshooting....................................................................................................................................... A-4
A-5. Ladder Logic Diagram .......................................................................................................................... A-13
A-6. Cross Reference..................................................................................................................................... A-36
A-7. Replacement Parts ................................................................................................................................. A-40
A-8. Documentation ...................................................................................................................................... A-41
vi Copyright 1999, 3M IPC. All rights reserved.
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3M-Matic 800rf Case Sealer Safety Information
Warning Label
The WARNING  Sharp Knife label, shown in Figure 1, is attached to the orange cut-off knife guard on both taping heads. The label warns the operator and service personnel of the very sharp knife located behind the guard and to keep hands out of this area except for tape loading and servicing the taping heads.
Warning
The taping heads are equipped with an orange knife guard that covers the knife. The taping heads must never be operated with the knife guards removed.
Figure 1. Warning Label
Danger Label
The DANGER  Hazardous Voltage Unplug Power Before Servicing label, shown in Figure 2, is attached to the front of the Electrical Control Panel, at the front of the machine. When power is on, opening the panel door allows access to +24 VDC and 220 VAC.
Figure 2. Danger Label
Copyright 1999, 3M IPC. All rights reserved. vii
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Safety Information 3M-Matic 800rf Case Sealer
Tape Threading Label
The Tape Threading Label, shown in Figure 3, is attached to the left side of both the upper and lower taping heads. This label provides a convenient tape threading diagram. More detailed tape loading and threading information is provided in this manual in Section 2, Installation.
Figure 3. Tape Threading Label
STOP Switches
The Model 800rf Type 39800 Case Sealer is equipped with three STOP switches. Their locations are shown in Figure 4. Pressing either of the red E­Stop switches stops the machine, removing electri­cal power and air pressure from the case sealer. To restart the machine, you must turn and release the E­Stop switch and then press the RESET button and the START button on the Electrical Control Panel.
Pressing the STOP button on the Electrical Control Panel stops the machine and does not remove power from the controller. To restart the machine, you must press the RESET button and then the START button.
Figure 4. STOP Switch Locations
viii Copyright 1999, 3M IPC. All rights reserved.
Page 13
3M-Matic 800rf Case Sealer Warranty
Equipment Warranty and Limited Remedy: THE FOLLOWING WARRANTY IS MADE IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTY OF MERCHANTABILITY, THE IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE AND ANY IMPLIED WARRANTY ARISING OUT OF A COURSE OF DEALING, A CUSTOMER OR USAGE OF TRADE:
3M sells its 3M-Matic
1. The Taping Head knife blades, springs and rollers will be free from all defects for ninety (90) days after
delivery.
2. All other Taping Head parts will be free from all defects for three (3) years after delivery.
3. All other parts will be free from all defects for ninety (90) days after delivery.
If any part is proved to be defective within its warranty period, then the exclusive remedy and 3Ms and sellers sole obligation shall be, at 3Ms option, to repair or replace the part, provided the defective part is returned immediately to 3Ms factory or an authorized service station designated by 3M. A part will be presumed to have become defective after its warranty period unless the part is received or 3M is notified of the problem no later than five (5) calendar days after the warranty period. If 3M is unable to repair or replace the part within a reasonable time, then 3M at its option, will replace the equipment or refund the purchase price. 3M shall have no obligation to provide or pay for the labor required to install the repaired or replacement part. 3M shall have no obligation to repair or replace: (1) those parts failing due to operation misuse, carelessness or due to any accidental cause other than equipment failure, or (2) parts failing due to non-lubrication, inadequate cleaning, improper operating environment, improper utilities or operator error.
Limitation of Liability: 3M and seller shall not be liable for direct, indirect, special, incidental or consequential damages based upon breach of warranty, breach of contract, negligence, strict liability or any other legal theory.
The foregoing Equipment Warranty and Limitation of Liability may be changed only by a written agreement signed by authorized officers of 3M and seller.
800rf Fully Automatic Random Case Sealer with the following warranties:
Copyright 1999, 3M IPC. All rights reserved. ix
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Warranty 3M-Matic 800rf Case Sealer
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3M-Matic 800rf Case Sealer Description and Specifications
Table of Contents
1. Description and Specifications ..................................................................................................................... 1-1
1-1. Intended Use ............................................................................................................................................. 1-1
1-2. Description ............................................................................................................................................... 1-2
1-3. Specifications ........................................................................................................................................... 1-3
1-4. Case Sealing Rate Approximation Formula .............................................................................................1-4
1-5. Machine Dimensions ................................................................................................................................1-5
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Description and Specifications 3M-Matic 800rf Case Sealer
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3M-Matic 800rf Case Sealer Description and Specifications
1. Description and Specifications
1-1. Intended Use
The 3M-Matic Model 800rf Type 39800 Automatic Random Case Sealer with AccuGlide II Taping Heads is designed to accept filled, regular slotted containers from an existing conveyor, fold the top flaps, and apply a C clip of Scotch brand Pres­sure-Sensitive Film Box Sealing Tape to the top and bottom center seams. Two side-drive belt assemblies convey the cases through the machine.
The 800rf Case Sealer is to be used with infeed and exit conveyors supplied by the customer. Do not attempt to run the case sealer without infeed and exit conveyors in place.
ü Note
In this manual, the end of the case sealer that accepts cases for taping is the infeed end. The end of the case sealer where the taped cases leave is the exit end. The side containing the Electrical Control Panel and the Pneumatic Control Panel is the front or left side of the machine, and the opposite side is the back or right side of the machine.
Figure 1-1 shows the 800rf Case Sealer with callouts to identify its major components.
Figure 1-1. 3M-Matic 800rf Case Sealer
3M-Matic, AccuGlide, and Scotch are trademarks of 3M, St. Paul, MN 55144-1000
Copyright 1999, 3M IPC. All rights reserved. 1-1
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Description and Specifications 3M-Matic 800rf Case Sealer
1-2. Description
The 800rf Case Sealer is controlled from two operator control panels located on the front left side of the case sealer. These control panels (Electrical Control Panel and Pneumatic Control Panel) have the most-used controls within easy reach of the operator. The case sealer is microprocessor-based and firmware con­trolled to maintain maximum and precise control over all operations within the case sealer.
The case sealer may be operated in Random, Fixed, or Bypass mode. A selector switch is located on the top of the Electrical Control Panel.
!
Caution
Never change operating modes while a box is in the case sealer. Change modes only after a box exits the case sealer and before the next box enters the case sealer.
In Random mode, the case sealer automatically
adjusts itself for a wide range of case sizes, providing a tape seal on the top and bottom of the cartons. Random mode is considered the standard operating mode.
In Fixed mode, the case sealer runs multiple
cartons of the same (fixed) size, providing a tape seal on the top and bottom of the cartons.
In Bypass mode, the case sealer passes certain
containers through the machine, providing a tape seal only on the bottom of the containers. The top of these containers is not sealed.
1-2 Copyright 1999, 3M IPC. All rights reserved.
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3M-Matic 800rf Case Sealer Description and Specifications
1-1. Specifications
Tape:
3M brand pressure-sensitive film box sealing tapes.
Tape Width:
Standard 3M-Matic 800rf Case Sealer. This model offers tape widths from 1-1/2 inches [36 millimeters] minimum to 2 inches [48 millimeters] maximum.
3M-Matic 800rf-3 Case Sealer. This model offers 3-inch wide upper and lower AccuGlide II Taping Heads for tape widths from 2 inches [48 millimeters] to 3 inches [72 millimeters].
Tape Roll Diameter:
Up to 15-1/2 inches [394 millimeters] maximum, on a 3-inch [76.2 millimeters] diameter core.
Box Dimensions:
Length: 8 inches [203 millimeters] minimum,
24 inches [610 millimeters] maximum.
Width: 5-1/2 inches [140 millimeters] minimum,
20 inches [508 millimeters] maximum.
Height: 6 inches [152 millimeters] minimum,
20 inches [508 millimeters] maximum.
Box Weight Capacity: (filled) 65 pounds [29 kilograms] maximum; minimum must be sufficient to hold case on the conveyor bed with bottom flaps flat.
Box Type:
Box board, 125 to 275 PSI bursting test, single wall A, B, or C flute.
ü Note
The case sealer accommodates most boxes within the size range identified above. However, if the ratio of box length (in the taping direction) to box height is
0.6 or less, several boxes should be test-run to ensure proper machine performance.
Operating Conditions:
o
Use in dry, relatively clean environments at 40
o
120
F [5oC to 49oC] with clean, dry boxes. The
F to
machine should not be washed down or subjected to conditions causing moisture condensation on compo­nents.
Machine Specifications:
Length: 86-3/4 inches [2.20 meters].
Width: 57 inches [1.45 meters].
Height: 74 inches [1.88 meters] minimum
with casters to 80 inches [2.03 meters] maximum with casters.
Weight: Unit uncrated, approximately
1130 pounds [513 kilograms]. Unit crated, approximately 1200 pounds [544 kilograms].
Case sealer bed height: Adjustable up from
factory-set height of 25-7/8 inches [657 millimeters] to 32 inches [815 millimeters] with casters.
Power Requirements:
Electrical: 208 to 240 VAC, 50/60 Hz, 5.5 Amps,
3-phase.
Pneumatic: Machine requires 75  140 PSIG
[5.2  9.5 BAR] 7.0 SCFM
3
[11.89 m
/h 21oC, 101 kPa] at the regulator, maximum at maximum cycle rate.
The optimum operating set point on the gauge is 95  100 PSIG.
Infeed Conveyor Speed: The customers infeed conveyor box delivery speed must not exceed 60 feet/minute.
!
Caution
Do not connect a lubricator or lubricated air to this machine. This machine has a non-lubricated air circuit.
DETERMINE THE BOX LIMITATIONS BY COMPLETING THIS FORMULA:
Box (tape) Length
> 0.6
Box Height
Copyright 1999, 3M IPC. All rights reserved. 1-3
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Description and Specifications 3M-Matic 800rf Case Sealer
1-1. Case Sealing Rate Approximation Formula
To determine the case sealing rate for your application:
1. Obtain a representative sample of boxes in the proportion that will be run through the machine. Use as many boxes as necessary to get an accurate sample.
Example:
1. Determine (add up) the
2. Determine (add up) the
3. Determine (add up) the
Number of boxes: _____________
Total length (inches): _____________
Total width (inches): _____________
Total height (inches): _____________
4. Divide the dimension totals by the number of boxes  to determine average length, width, and height.
Total length _____________ = ____________ Average length Number of boxes
Total width _____________ = ____________ Average width Number of boxes
Total height _____________ = ____________ Average height Number of boxes
total length of all boxes.
total width of all boxes.
total height of all boxes.
800rf Case Sealing Rate (cases per minute)
Rate = 5.97 + (0.42 X ave. length)  (1.06 X ave. width) + (0.72 X ave. height)
1-4 Copyright 1999, 3M IPC. All rights reserved.
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3M-Matic 800rf Case Sealer Description and Specifications
1-1. Machine Dimensions
Figure 1-2 shows machine dimensions for the 800rf Case Sealer. The dimensions are given in both inches and millimeters. For example, 20.00 inches [508 millimeters] is shown as 20.00 [508].
Figure 1-2. Machine Dimensions
Copyright 1999, 3M IPC. All rights reserved. 1-5
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Description and Specifications 3M-Matic 800rf Case Sealer
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3M-Matic 800rf Case Sealer Installation
Table of Contents
2. Installation .....................................................................................................................................................2-1
2-1. General ............................................................................................................................................... 2-1
2-2. Unpacking ..........................................................................................................................................2-2
2-3. Setup Procedure ................................................................................................................................. 2-3
2-3-1. Case Sealer Bed Height ........................................................................................................ 2-3
2-3-2. Rear Emergency Stop Switch Installation ............................................................................ 2-3
2-3-3. Warning Beacon Installation ................................................................................................. 2-4
2-3-4. Pneumatic Connection .......................................................................................................... 2-4
2-3-5. Air Pressure Indicator ........................................................................................................... 2-5
2-3-6. Air Pressure Regulators ........................................................................................................ 2-5
2-3-7. Electrical Connection............................................................................................................ 2-6
2-4. Tape Loading ..................................................................................................................................... 2-8
2-4-1. Top Tape Head Loading ........................................................................................................ 2-9
2-4-2. Bottom Tape Head Loading ................................................................................................ 2-10
2-5. Tape Drum Friction Brake ............................................................................................................... 2-11
2-6. Checkout Inspection (to be performed by an authorized 3M Service Technician) .......................... 2-11
2-6-1. Static Tests .......................................................................................................................... 2-11
2-6-2. Programmable Controller Inputs and Outputs .................................................................... 2-12
2-6-3. Dynamic Tests ..................................................................................................................... 2-12
2-7. Placing 800rf Case Sealer in Production Line .................................................................................2-12
2-8. Special Setup Procedure .................................................................................................................. 2-12
2-8-1. Relocating Pneumatic and Electrical Control Panels ......................................................... 2-12
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Installation 3M-Matic 800rf Case Sealer
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3M-Matic 800rf Case Sealer Installation
2-1. General
The following instructions are presented in the order recommended for installing and setting up the 800rf Case Sealer, as well as for learning the operating functions and adjustments. Following these instruc­tions step-by-step results in a thorough understand­ing of the case sealer and its installation in a produc­tion line that best uses the many features of the case sealer. Refer to Figure 2-1 for nomenclature.
Uncrating and setting up the case sealer consists of four steps:
1. Uncrating the equipment.
2. Assembling the case sealer as described in this section.
3. Providing the electrical and pneumatic connec­tions.
4. Installation of the case sealer in a production line.
Once you decide on a schedule to accomplish these steps, contact:
3M Packaging Systems Division Customer Support Center Phone 1-800-328-1390
A 3M technician will be sent to your site to perform a final checkout inspection.
ü Note
We recommend that you do not operate the case
sealer in a production situation until the final check-
out inspection is complete. For the final checkout
inspection, have a sufficient supply of cases in
representative sizes and weights to check the case
sealer under normal operating conditions.
Figure 2-1. 3M-Matic 800rf Case Sealer
Copyright 1999, 3M IPC. All rights reserved. 2-1
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Installation 3M-Matic 800rf Case Sealer
2-2. Unpacking
ü Note
It is the responsibility of the customer to uncrate the case sealer. Lifting equipment (forklift, overhead crane, etc.) is necessary to lift the case sealer from its pallet.
The case sealer is delivered in one crate.
Perform the following inspection upon receipt of the case sealer.
1. Inspect the shipping crate for damage that could indicate internal damage to the case sealer.
Report any damage, missing parts, or other problems to:
3M Packaging Systems Division Customer Support Center Phone 1-800-328-1390
2. Dismantle the crate.
3. Inspect the case sealer and uninstalled compo­nents for damage or missing parts. The crate should also contain the following:
One tool box containing:
1 wrench, tube, 17 mm 1 wrench, box/open, 13 mm & 10 mm 1 wrench, box/open, 8 mm & 7 mm 1 wrench, open end, 25 mm 1 wrench, hex key, 3 mm 1 wrench, hex key, 4 mm 1 wrench, hex key, 5 mm 1 wrench, hex key, 6 mm 1 spring, main upper (78-8070-1274-1) 1 spring, main lower (78-8070-1273-3) 4 springs, cutter (78-8052-6602-6) 2 blades, cutter (78-8017-9173-8) 1 tool, tape threading (78-8076-4726-4)
4. Report any damage, missing parts, or other problems to:
3M Packaging Systems Division Customer Support Center Phone 1-800-328-1390
5. Move the case sealer to the point of use, but do not place it into production until after the 3M technician completes the checkout inspection.
One latching emergency stop switch with bracket
(electrically connected, but not mounted in place)
One warning beacon with bracket (electrically
connected, but not mounted in place)
2-2 Copyright 1999, 3M IPC. All rights reserved.
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3M-Matic 800rf Case Sealer Installation
2-3. Setup Procedure
2-3-1. Case Sealer Bed Height
The legs on the case sealer can be adjusted to obtain different bed heights from the factory set-point. The bed height can be set from 25-7/8 inches [657 mm] minimum through 32 inches [815 mm] maximum. Set the bed height as follows:
1. Block up the case sealer frame to allow adequate leg adjustment.
2. Using a 6 mm hex key wrench, loosen, but do not remove, two M8 x 16 mm socket-head cap screws in one leg. Refer to Figure 2-2.
2-3-2. Rear Emergency Stop Switch
Installation
A latching Emergency Stop (E-Stop) switch is electrically connected to the case sealer, but not mounted to the machine. Install this E-Stop switch on the rear side of the case sealer.
1. Remove the protective wrap from the E-Stop switch and bracket assembly.
2. Secure the E-Stop switch bracket to the rear sliding door support bracket with the socket-head screw provided. Refer to Figure 2-3.
Figure 2-3. Rear E-Stop Switch Installation
Figure 2-2. Bed Height Adjustment
3. Using the height label as a guide, adjust the leg length to the desired conveyor bed height. Re­tighten the two screws to secure the leg.
4. Adjust the five remaining legs in the same way.
Copyright 1999, 3M IPC. All rights reserved. 2-3
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Installation 3M-Matic 800rf Case Sealer
2-3-3. Warning Beacon Installation
A red warning beacon is electrically connected to the case sealer, but not mounted to the machine. Install this warning beacon on top of the frame support member to which it is connected.
1. Remove the protective wrap from the warning beacon and L-bracket assembly.
2. Remove the top hex-head screw from the frame support member. Refer to Figure 2-4.
3. Secure the warning beacon L-bracket to the frame support member with the screw just removed.
2-3-4. Pneumatic Connection
The case sealer requires a compressed air supply of 75  140 PSIG [5.2  9.5BAR] 7.0 SCFM [11.89m
o
C, 101kPa] maximum at maximum cycle rate. The
21 optimum operating set-point on the gauge is 95  100 PSIG. As shown in Figure 2-5, an On/Off Valve, Main Air Pressure Regulator, and Filter are provided to service the air supply.
Connect the air supply line to the Main Air Pressure Regulator On/Off Valve.
ü Note
The air supply On/Off Valve has provisions for
lockout/tagout according to plant regulations.
3
/h
Figure 2-4. Warning Beacon Installation
Figure 2-5. Air Supply Components
2-4 Copyright 1999, 3M IPC. All rights reserved.
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3M-Matic 800rf Case Sealer Installation
2-3-5. Air Pressure Indicator
The Pneumatic Control Panel (Figure 2-6) is equipped with an Air Pressure Indicator to show, in red, when the air circuit is energized. The Air Pressure Indicator is located in the top center of the control panel.
2-3-6. Air Pressure Regulators
There are four air pressure regulator control knobs located on the underside of the Pneumatic Control Panel. Their corresponding gauges are located across the top of the Pneumatic Control Panel. Refer to Figure 2-6.
Refer to the Adjustments section of this manual for the recommended set points for each regulator (Counter-Balance Pressure Regulator, Paddle Pres­sure Regulator, Side Belt Pressure Regulator, and Box Centering Pressure Regulator). Also refer to the label located on the lower front portion of the Pneu­matic Control Panel.
To adjust any of these air pressure regulators, turn its control knob clockwise (CW) to increase pressure and counterclockwise (CCW) to decrease pressure.
Figure 2-6. Pneumatic Control Panel
Copyright 1999, 3M IPC. All rights reserved. 2-5
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Installation 3M-Matic 800rf Case Sealer
2-3-7. Electrical Connection
!
Caution
Before making the electrical connection, make sure that the red Latching Emergency Stop switch located on the Electrical Control Panel is depressed. Also ensure that all packaging materials and tools are removed from the case sealer.
The case sealer and its Electrical Control Panel are wired for 208  240 VAC, 50/60 Hz, 3-phase power and a power cord is connected. However, no power plug is supplied. The power cord can be wired directly into a power distribution box or a plug can be installed. The recommended plug is a L15-20, 4-pin twist-lock. Possible wire code combinations are:
Black  Phase X or Black  Phase X White  Phase Y Brown  Phase Y Red  Phase Z Blue  Phase Z Green  Ground Yel/Grn  Ground
1. Turn the electrical power on by rotating the Main Disconnect switch CW. Refer to Figure 2-8. The white POWER indicator lights to show that power is available. Refer to Figure 2-7.
2. The red lights on the Electrical Control Panel indicate a Fault/E-Stop switch condition. Turn the red latching E-Stop switch CW to release the switch. The red FAULT and E-STOP/ SLIDING DOOR indicators should turn off.
3. Press the blue RESET button on the Electrical Control Panel. You should observe air-powered movement of the Upper Head Assembly and the Rear Flap Folding Arm, which moves to an upright (extended) position.
4. Press the green START button on the Electrical Control Panel. Pressing this button applies electrical power to the two side belt drive motors and the infeed roller drive motors. The RUN indicator should light.
Viewing the case sealer from its infeed end, you should observe the right/rear drive belt turning in a CW direction and the left/front drive belt turning in a CCW direction. With the belts rotating as described, they will draw a carton into the machine. This is the normal operating condition.
ü Note
If the drive belts rotate in reverse, interchange any two of the black, white, or red 208  220 VAC wires at the plug or power distribution box. This will restore the motors to the correct rotation.
2-6 Copyright 1999, 3M IPC. All rights reserved.
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3M-Matic 800rf Case Sealer Installation
Figure 2-7. Electrical Control Panel
(Top View)
Figure 2-8. Electrical Control Panel
(Front View)
Copyright 1999, 3M IPC. All rights reserved. 2-7
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Installation 3M-Matic 800rf Case Sealer
2-4. Tape Loading
Warning!
Turn air and electrical supplies off and disconnect before servicing taping heads. Never attempt to work on the taping heads or load tape when the box drive system is running. Each taping head is equipped with an extremely sharp cut-off knife. Before working with the taping heads or attempting to load/thread tape, identify the knife locations. Keep hands out of these areas except as necessary to service the taping heads. Failure to comply with these warnings can result in severe personal injury and/or equipment damage.
Figure 2-9 shows the components of the top taping head.
The taping heads are pre-set to accommodate 2-inch [48 mm] wide tape rolls. To use and apply 1-1/2 inch [36 mm] or 1-3/4 inch [42 mm] wide tapes, refer to the Adjustments section for set up information.
A tape-threading tool is shipped with the case sealer for tape loading convenience. Retain the tool for continued use in the tape loading operation. For operator assistance, a threading diagram is applied to the taping heads. However, it is recommended that the more detailed instructions and illustrations in this manual be referred to the first few times the tape is loaded until the operator becomes thoroughly familiar with the tape loading operation.
For convenience in loading, the bottom taping head can be removed by lifting it out of the bed of the case sealer. The upper head assembly must be in its uppermost position to load tape in the top tape head.
Figure 2-9. Top Taping Head Components
2-8 Copyright 1999, 3M IPC. All rights reserved.
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3M-Matic 800rf Case Sealer Installation
2-4-1. Top Tape Head Loading
1. Turn off the Main Disconnect Switch on the Electrical Control Panel.
2. Insert the tape-threading tool downward around the rollers, as shown in Figure 2-10.
Figure 2-11. Attach Tape to Threading Tool
Figure 2-10. Insert Tape Threading Tool
3. Place the tape roll on the drum to dispense tape from the bottom of the roll toward the infeed end of the machine with the tape adhesive-side up. Attach the tape leading end to the upper end of the tape-threading tool, as shown in Figure 2-11.
4. Manually turn the tape roll to create slack tape while pulling the tape-threading tool through the tape-applying mechanism until the tool is in alignment with the applying roller.
5. Cut off the excess tape with a scissors or knife below the applying roller. Refer to Figure 2-12.
Retain the tape-threading tool for future use.
Figure 2-12. Cut Off Tape
Copyright 1999, 3M IPC. All rights reserved. 2-9
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Installation 3M-Matic 800rf Case Sealer
2-4-2. Bottom Tape Head Loading
The bottom taping head is loaded and threaded in the same manner as the top taping head. For ease in loading, lift the bottom taping head from the con­veyor bed and follow the top tape head loading procedure. Refer to Figure 2-13.
Figure 2-13. Bottom Taping Head
2-10 Copyright 1999, 3M IPC. All rights reserved.
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3M-Matic 800rf Case Sealer Installation
2-5. Tape Drum Friction Brake
1. Refer to Figure 2-14. Turn the locking nut clockwise to increase the braking force or coun­terclockwise to decrease the force.
2. Adjust the friction brake for the minimum braking force that prevents excessive overtravel.
ü Note
Excessive braking force causes poor tape application and may lead to tape tabbing on the trailing tape leg.
2-6. Checkout Inspection
(to be performed by an authorized 3M Service Technician)
2-6-2. Static Tests
1. Connect the air supply line and the electrical power to the case sealer and power up the ma­chine.
a. Turn the Air On/Off Valve to the ON posi-
tion.
b. Turn the Main Disconnect Switch on the
Electrical Control Panel to the ON position.
c. Press the RESET button on the Electrical
Control Panel.
2. Verify the following conditions:
Air Pressure Indicator on the Pneumatic
Control Panel is red, showing that air pressure is applied to the system, the rear flap folding arm is extended, and the flap folder is re­tracted.
Figure 2-14. Friction Brake Adjustment
Paddle is down.
Side belts are out.
Box centering rails are out.
Box stop gate is up.
3. Check the Main Input Air Pressure Regulator. The pressure gauge should read 95 PSIG.
a. If the pressure is lower, check the input
pressure at the source. If the pressure is lower than 75 PSIG, there is not enough pressure to operate the case sealer properly.
b. If the pressure is above 95 PSIG, adjust the
air pressure regulator to read 95 PSIG on the gauge. (CW  increases pressure, CCW  decreases pressure).
Copyright 1999, 3M IPC. All rights reserved. 2-11
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Installation 3M-Matic 800rf Case Sealer
4. Check the Box Centering Pressure gauge on the Pneumatic Control Panel. Refer to Figure 2-15. The gauge should read 40  60 PSIG. If the pressure does not fall within this range, adjust the pressure regulator (CW  increases pressure, CCW  decreases pressure).
5. Check the Side Belt Pressure gauge on the Pneumatic Control Panel. The gauge should read 40  60 PSIG. If necessary, adjust the Side Belt Pressure Regulator to this setting. (CW  in­creases pressure, CCW  decreases pressure).
6. Check the Paddle Pressure gauge on the Pneu­matic Control Panel. The gauge needle should be at 7 PSIG. Adjust as needed.
7. Check the Counter-Balance Pressure gauge on the Pneumatic Control Panel. The gauge should read 40  60 PSIG. If the pressure does not fall within this range, adjust the pressure regulator (CW  increases pressure, CCW  decreases pressure).
Figure 2-15. Pneumatic Control Panel
2-12 Copyright 1999, 3M IPC. All rights reserved.
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3M-Matic 800rf Case Sealer Installation
8. Press the START button on the Electrical Control Panel. Refer to Figure 2-16. Verify that the side belts and the infeed rollers start turning.
ü Note
If pressing the START button does not result in continuous running of the side belt drive motors and the infeed drive motors, then a Fault Condition exists. Check the motor overload circuit breakers OL1, OL2, OL3, and OL4, which are the most likely cause. These circuit breakers are located inside the Electrical Control Panel. Make sure the green START buttons are all pushed in.
Figure 2-16. Electrical Control Panel
9. Check the operation of the red latching Emergency Stop switches (one E-Stop switch is located on the Electrical Control Panel and the other switch is located at the rear of the machine) and the STOP button on the Electrical Control Panel. Verify that the drive motors stop when either E-Stop switch is pressed or the STOP button is pressed.
The case sealer must be restarted each time it stops before checking the next switch. Restart the machine by pressing the RESET button and then the START button.
Caution
!
If the EMERGENCY STOP switches or the STOP button do not function properly, do not continue with the checkout. Refer to the Theory of Operation and Troubleshooting sections and correct the situation before continuing.
Warning!
Steps 10 and 11 require opening the Electrical Control Panel door. This exposes 220 VAC. Be cautious or personal injury can result.
Copyright 1999, 3M IPC. All rights reserved. 2-13
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Installation 3M-Matic 800rf Case Sealer
10. Check the operation of the electrical interlocks for the sliding doors. With the drive motors running, move each sliding door, one at a time, from its closed position. Verify that the drive motors stop and that they cannot be restarted by pressing the RESET button and then the START button until the door is closed.
Verify also that when the door is open only OUTPUT LEDs 13 and 14 are ON and no INPUT LEDs are displayed on the Programmable Con­troller located inside of the Electrical Control Panel.
11. Refer to Figure 2-17. Check the operation of the photocells PC1 through PC6. Cover each photo­cell in turn and observe the associated INPUT LED number displayed on the Programmable Controller. The INPUT LED should be ON when the associated photocell is covered.
Photocell INPUT LED PC1 IN 4 PC2 IN 5 PC3 IN 6 PC4 IN 7 PC5 IN 8 PC6 IN 9
Figure 2-17. Photocell Locations
2-14 Copyright 1999, 3M IPC. All rights reserved.
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3M-Matic 800rf Case Sealer Installation
2-6-2. Programmable Controller Inputs and
Outputs
Figure 2-18 shows the SLC 500 Programmable Controller used in the 3M-Matic 800rf Type 39800 Case Sealer. The Programmable Controller is located inside of the Electrical Control Panel.
Figure 2-18. SLC 500 Programmable Controller
Copyright 1999, 3M IPC. All rights reserved. 2-15
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Installation 3M-Matic 800rf Case Sealer
Figure 2-19 shows the Programmable Controller lights that turn on during the following startup conditions.
POWER ON RESET START
POWER POWER POWER PC RUN PC RUN PC RUN INPUT 3 INPUT 0, 3, 11, 15 INPUT 0, 3, 11, 15
OUTPUT 1, 3 , 7, 12, 15
Figure 2-19. Programmable Controller Startup Conditions
2-16 Copyright 1999, 3M IPC. All rights reserved.
Page 41
3M-Matic 800rf Case Sealer Installation
Table 2-1 lists the INPUT LEDs displayed on the Programmable Controller, the names of the input signals that feed the LEDs, and the conditions that cause the LEDs to turn ON or OFF.
View the LEDs with the Main Disconnect Switch and the Air On/Off Valve turned to their ON positions.
Table 2-1. Programmable Controller Inputs
INPUT LED Input Signal Name LED Condition
0 Stop OFF when STOP button is pushed. 1 Start ON when START button is pushed. 2 Reset ON when RESET button is pushed. 3 E-Stop/Sliding Door OFF when E-Stop switch is pushed or door is opened. 4 PC1 ON when photocell PC1 is blocked. 5 PC2 ON when photocell PC2 is blocked. 6 PC3 ON when photocell PC3 is blocked. 7 PC4 ON when photocell PC4 is blocked. 8 PC5 ON when photocell PC5 is blocked.
9 PC6 ON when photocell PC6 is blocked. 10 Box Height (Paddle) Switch ON when paddle is pushed up. 11 Head Upper Limit Switch ON when upper head assembly is at its upper limit. 12 Minimum Width Switch ON when side belt assemblies close to innermost position. 13 Fixed Mode Switch ON when selector switch is set to FIXED position. 14 Bypass Mode Switch ON when selector switch is set to BYPASS position. 15 Low Air Pressure Switch ON when air pressure is above 50 PSIG. 16 Flap Folder Arm Switch ON when cylinder piston is near reed switch. 17 Overload ON when any motor overload switch trips. 18 Not used 19 Not used 20 Not used 21 Not used 22 Not used 23 Not used
Copyright 1999, 3M IPC. All rights reserved. 2-17
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Installation 3M-Matic 800rf Case Sealer
Table 2-2 lists the OUTPUT LEDs displayed on the Programmable Controller, the names of the output signals that feed the LEDs, and the conditions that cause the LEDs to turn ON or OFF.
View the LEDs with the Main Disconnect Switch and the Air On/Off Valve turned to their ON positions.
Table 2-2. Programmable Controller Outputs
OUTPUT LED Output Signal Name LED Condition
0 Side Belt Lock ON when side belts lock. 1 Side Drive Motors ON when side belt drive motors are running. 2 Flap Folder Arm ON when flap folder arm is down. 3 Infeed Gate ON when infeed gate is down. 4 Centering Rails ON when photocell PC1 is blocked. 5 Side Drive Assembly Closing ON when photocell PC3 is blocked. 6 Paddle Cylinder ON when paddle is pushed up. 7 Fork Cylinder ON when fork is up. 8 Head Assembly Cylinder Brakes ON when brakes turn on.
9 Head Raising Cylinder Lower Port ON when upper head assembly lowers. 10 Head Raising Cylinder Upper Port ON when upper head assembly raises. 11 Rear Flap Folder ON when rear flap folder folds last minor flap. 12 Infeed Motors (2) ON when infeed motors are running. 13 Alarm ON when any fault condition exists. 14 E-Stop Signal ON when either E-Stop switch is pushed. 15 Ready Signal ON when START button is pushed.
2-18 Copyright 1999, 3M IPC. All rights reserved.
Page 43
3M-Matic 800rf Case Sealer Installation
2-6-3. Dynamic Tests
The following procedures check the actual operation
of the 800rf Case Sealer. The following conditions
must be observed.
Electrical power and compressed air are available
and turned on.
The four safety doors are in their closed posi-
tions.
Cases should have:
the bottoms folded closed
a minimum weight to hold the case on the
conveyor bed with the bottom flaps flat
the front and rear flaps inside the side flaps
1. Apply air pressure and electrical power and press the RESET and the START buttons on the Electrical Control Panel.
2. If applicable, run the longest box (19 inches to 24 inches) through the case sealer. Check the following sequence of events.
a. The box feeds from the infeed conveyor
rollers. The box is centered by the box centering rails and the box stop gate moves up.
f. The side belts restart. g. Just before the sides of the box are folded
down, the rear flap of the box is folded down into place.
ü Note
The timing of step g will vary depending on the length of the box.
h. The sides of the box are folded down. i. The top flap compression rollers touch the
sides of the top of the box without causing the side flaps to overlap.
j. C-clips of tape are applied to both the top and
bottom center seams of the box. k. The box exits the case sealer. l. The head rises to its upper position, the side
belts return to their outer position, the fork
rises to its normal position, and the box stop
gate lowers to allow the next box to be fed
into the machine.
ü Note
If any of the steps outlined above do not occur correctly, refer to the appropriate adjustment in the Adjustments section of this manual.
b. The box is released and moves to the side
belts.
c. The side belts move inward and hold the box,
driving it toward the fork.
d. The box arrives at the fork and the side belts
stop driving the box.
e. The head lowers to the box, stopping at the
top of the box without distorting it.
3. If applicable, repeat the procedure outlined in step 2 using the shortest box (8 inches to 13 inches).
4. If applicable, repeat the procedure outlined in step 2 using a box between 12 and 19 inches.
5. Now that a representative sample of boxes has been checked and appropriate adjustments have been made, flood the infeed line with a random array of boxes and check for consistent opera­tion of the case sealer.
Copyright 1999, 3M IPC. All rights reserved. 2-19
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Installation 3M-Matic 800rf Case Sealer
2-7. Placing 800rf Case Sealer in
Production Line
When installing the 800rf Case Sealer into a produc­tion line, ensure compliance with the following requirements:
The case sealer must be level.
The customers infeed conveyor may be powered
or inclined to the case sealer.
The customers infeed conveyor box delivery
speed CANNOT exceed 60 ft/min.
The customers exit conveyor may be powered or
inclined whichever positively conveys boxes away from the exit end of the case sealer.
The width of the customers infeed conveyor and
exit conveyor should fall within 22 inches [560 mm] minimum to 38 inches [965 mm] maximum.
Figure 2-20 shows the 800rf Case Sealer connected to customer-supplied infeed and exit conveyors.
!
Caution
The 800rf Case Sealer must not be run in a production line without being joined to the customers infeed conveyor. This is to restrict an operator from being exposed to moving case sealer components during its operation.
Figure 2-20. Typical Conveyor Setup
2-20 Copyright 1999, 3M IPC. All rights reserved.
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3M-Matic 800rf Case Sealer Installation
2-8. Special Setup Procedure 2-8-1. Relocating Pneumatic and Electrical
Control Panels
Warning!
Turn off electrical power and air supply and disconnect power cord from electrical supply before beginning this procedure. Failure to comply with these warnings can result in severe personal injury and/or equipment damage.
Relocating the case sealer Pneumatic and Electrical Control Panels from their standard position which is the left/front side, as viewed from the infeed end of the machine, enables the case sealer to be operated from the right/rear side of the machine.
At various steps of this procedure it is recommended that two (2) people be involved in moving certain components from the front to the rear of the case sealer.
ü Note
Following these procedures will accomplish having the control panels located to the right/rear of the case sealer and will orient the Electrical Control Panel on the left and the Pneumatic Control Panel on the right, as viewed by the operator facing the rear side of the machine.
Removing Air On/Off Valve/Regulator/Filter, Pneumatic Control Panel, and Brackets
1. Disconnect the air supply from the Air On/Off Valve.
2. Open the Pneumatic Control Panel (use 8 mm hex wrench) to assist in removing the input air line from the air outlet on the Main Air Pressure Regulator. Push in and hold the collet (release ring) and pull the air line free. Refer to Figure 2-21.
To prevent the case sealer from rolling, lock all the casters before starting these procedures.
Figure 2-21. Disconnecting Air Line
Copyright 1999, 3M IPC. All rights reserved. 2-21
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Installation 3M-Matic 800rf Case Sealer
3. Disconnect the plastic conduit at the Electrical Control Panel, which connects to the Pneumatic Control Panel. This conduit contains the electri­cal wires for the valve solenoids.
4. Slide the left front sliding door all the way to the right to provide additional access.
5. Remove the Air On/Off Valve/Regulator/Filter bracket.
a. Remove the 2 socket-head screws (6 mm)
securing the bracket to the mainframe bracket. Refer to Figure 2-22.
b. Set this bracket (with Air On/Off Valve/
Regulator/Filter attached) aside for use later.
6. Prepare two (2) blocks (10 long x 8 wide x 18 high). These blocks will be used to support the control panels later in this procedure.
!
Caution
Blocks must be capable of supporting the weight of the Electrical Control Panel, which is about 50 pounds [22.7 kg].
7. Remove the Pneumatic Control Panel. a. Place a block under the Pneumatic Control
Panel.
b. Remove the 4 socket-head screws (6 mm)
securing the control panel to the left and right
brackets. Refer to Figure 2-23. c. Save these screws for use later. d. Ease the control panel onto the block. Make
sure the block is centered under the control
panel so the panel is stable.
Figure 2-22. Removing Air On/Off Valve/
Regulator/Filter Bracket
Figure 2-23. Removing Pneumatic Control Panel
2-22 Copyright 1999, 3M IPC. All rights reserved.
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3M-Matic 800rf Case Sealer Installation
8. Remove the left and right mainframe brackets that support the Pneumatic Control Panel. Refer to Figure 2-24.
a. Remove 8 socket-head screws (6 mm)
securing the left support bracket to the case sealer (4 screws holding the bracket to the mainframe, and 4 screws holding the 2 L brackets).
b. Remove 4 socket-head screws (6 mm)
securing the right support bracket to the case sealer.
c. Save these screws and brackets for use later.
Moving Support Brackets and Installing Pneu­matic Control Panel
9. Install the left support bracket and L brackets (removed from the front of the machine) at the rear of the machine. Refer to Figure 2-25. Secure the brackets with the socket-head screws (6 mm).
10. Remove the right mainframe bracket from the rear of the machine and install it at the front left of the case sealer. Refer to Figure 2-25.
12. Install the Pneumatic Control Panel at the rear of the case sealer.
a. Lift the Pneumatic Control Panel from the
block and slide it through the undercarriage to the rear of the case sealer.
b. Block the control panel and then lift it and
carefully set it onto the support brackets.
c. Hold the control panel in place and secure it
to the support brackets with 4 socket-head screws.
a. Remove the 6 socket-head screws (6 mm)
securing the mainframe bracket to the case sealer (4 screws holding the bracket to the mainframe, and 2 screws holding the bracket to the underside of the door frame).
b. Install this bracket at the front left of the case
sealer. Secure the bracket to the mainframe with 4 socket-head screws, and secure the bracket to the underside of the door frame with 2 socket-head screws.
11. Install the right support bracket (removed from the front of the machine) at the rear right of the case sealer. Refer to Figure 2-25. Secure the bracket to the mainframe with 4 socket-head screws.
Figure 2-24. Removing Support Brackets for
Pneumatic Control Panel
Copyright 1999, 3M IPC. All rights reserved. 2-23
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Installation 3M-Matic 800rf Case Sealer
Figure 2-25. Moving Support Brackets for Pneumatic Control Panel
2-24 Copyright 1999, 3M IPC. All rights reserved.
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3M-Matic 800rf Case Sealer Installation
Installing Air On/Off Valve/Regulator/Filter
13. Locate the Air On/Off Valve/Regulator/Filter and bracket.
14. Rotate the bracket 180°. a. Remove the lower socket-head screw (4
mm) and loosen the upper screw, but do not remove it. Refer to Figure 2-26.
b. Punch a hole in the label. Then rotate the
bracket 180°. The label will be upside-down (a replacement label is available and may be ordered as replacement parts are or­dered).
c. Secure the Air On/Off Valve/Regulator/
Filter to the bracket by installing the lower socket-head screw and tightening the upper screw. Refer to Figure 2-27.
15. Mount the bracket with the Air On/Off Valve/ Regulator/Filter to the left bracket that supports the Pneumatic Control Panel.
Figure 2-26. Air On/Off Valve/Regulator/Filter
and Bracket
Figure 2-27. Air On/Off Valve/Regulator/Filter
and Bracket Rotated 180°
Copyright 1999, 3M IPC. All rights reserved. 2-25
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Installation 3M-Matic 800rf Case Sealer
16. Remove and separate the Air On/Off Valve from the Regulator/Filter.
a. Loosen the hex screw in the bracket that
holds the two assemblies together. Refer to Figure 2-28.
b. Separate the Air On/Off Valve from the
Regulator/Filter by removing both assem­blies from the bracket.
17. Rotate the Regulator/Filter assembly 180°. a. Swap the air gauge and air plug. Do this by
unscrewing the gauge and the plug, then install the gauge in the hole previously containing the plug, and vice versa.
b. Remove the air outlet and install it on the
opposite side of the regulator body.
c. Remove the filter bowl and shield by sliding
the lock down, rotating the unit in either direction, and separating the unit from the regulator body.
d. Install the filter bowl and shield so the lock
is located directly under the gauge.
18. Install the Air On/Off Valve and Regulator/ Filter so the air outlet on the Regulator/Filter is facing the Pneumatic Control Panel and the Air On/Off Valve is facing the Electrical Control Panel. Refer to Figure 2-29.
a. Place the two assemblies in the bracket that
holds them together and tighten the hex screw.
Figurer 2-28. Separate Air On/Off Valve from
Regulator/Filter
Figurer 2-29. Air On/Off Valve/Regulator/Filter
Reconfigured
2-26 Copyright 1999, 3M IPC. All rights reserved.
Page 51
3M-Matic 800rf Case Sealer Installation
19. Connect the air line from the Pneumatic Control Panel to the air outlet on the regulator body.
a. Open the Pneumatic Control Panel (8 mm
hex wrench) and remove the center of the left knockout grommet.
b. Locate the input air line, pull it out and loop
it around, then route it through the hole in the left grommet (be careful not to kink the air hose). Refer to Figure 2-30.
c. Connect the input air line to the air outlet by
inserting the air line fully into the collet and pulling gently back to lock the air line into place.
Figure 2-30. Rerouting Input Air Line
Copyright 1999, 3M IPC. All rights reserved. 2-27
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Installation 3M-Matic 800rf Case Sealer
Removing Electrical Control Panel
20. Remove the Electrical Control Panel. This step requires two people.
a. Disconnect the large electrical connector and
the two smaller infeed motor electrical connectors located under the Electrical Control Panel.
b. Place two (2) blocks (described in Step 6)
under the Electrical Control Panel.
c. While holding the control panel firmly
against the support brackets, remove the 4 socket-head screws (6 mm) securing the panel to the left and right brackets. Refer to
Figure 2-31. d. Save these screws for use later. e. Ease the control panel onto the blocks. Make
sure the blocks are centered under the control
panel so the panel is stable. Be careful not to
damage the electrical connectors. f. Carefully move the blocked Electrical
Control Panel aside for later work.
Moving Support Brackets and Installing Electrical Control Panel
21. Slide both sliding doors all the way to the exit end of the machine to provide additional access.
22. Remove the right support bracket from the front of the machine and install it at the rear right of the case sealer.
a. Remove 6 socket-head screws (6 mm)
securing the right support bracket to the case sealer (4 screws holding the bracket to the mainframe, and 2 screws holding the bracket to the two L brackets attached to the under­side of the door frame). Refer to Figure 2-32.
b. Install this bracket at the rear right of the
case sealer. Refer to Figure 2-33. Secure the bracket to the mainframe with 4 socket-head screws.
Figure 2-32. Removing Support Brackets for
Electrical Control Panel
Figure 2-31. Removing Electrical Control Panel
2-28 Copyright 1999, 3M IPC. All rights reserved.
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3M-Matic 800rf Case Sealer Installation
Figure 2-33. Moving Support Brackets for Electrical Control Panel
23. Remove the mainframe bracket and E-Stop switch from the rear left of the machine and install the mainframe bracket at the front right of the case sealer. Refer to Figure 2-33.
a. Remove 1 socket-head screw securing the
E-Stop switch and bracket to the mainframe bracket. Set the E-Stop switch aside; it will be installed later.
b. Remove 6 socket-head screws (6 mm)
securing the mainframe bracket to the case sealer (4 screws holding the bracket to the mainframe, and 2 screws holding the bracket to the two L brackets attached to the under­side of the door frame).
c. Install this bracket at the front right of the
case sealer. Secure the bracket to the main­frame and L brackets with 6 socket-head screws.
24. Remove the left support bracket from the front of the machine and install it at the rear left of the case sealer. Refer to Figure 2-33.
a. Remove 4 socket-head screws (6 mm)
securing the left support bracket to the case sealer.
b. Install this bracket at the rear left of the case
sealer. Secure the bracket to the mainframe and L brackets with 6 socket-head screws.
25. Install the Electrical Control Panel at the rear of the case sealer. This step requires two people.
a. With one person on each side, lift the
Electrical Control Panel from the blocks and carefully set it onto the support brackets.
b. Hold the control panel in place and secure it
to the support brackets with 4 socket-head screws.
Copyright 1999, 3M IPC. All rights reserved. 2-28
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Installation 3M-Matic 800rf Case Sealer
26. Connect the electrical connectors and cables to the Electrical Control Panel.
a. Route the electrical connectors and cables
through the undercarriage to the rear of the case sealer.
b. Connect the large electrical connector and
the two smaller infeed motor electrical connectors to the receptacles located under the Electrical Control Panel.
c. Connect the plastic conduit from the Pneu-
matic Control Panel to the receptacle located under the Electrical Control Panel.
27. Install the E-Stop switch. a. Locate the E-Stop switch and gently pull
sufficient wire (extra wire is coiled in the frame) from the frame to route the E-Stop switch under the machine to the front right mainframe bracket.
b. Secure the E-Stop switch bracket to the
mainframe bracket with 1 socket-head screw. Refer to Figure 2-34.
Verify Correct Operation
28. Close all four sliding doors to engage the interlock switches.
29. Connect the main air supply to the Air On/Off Valve.
30. Connect the power cord to the electrical supply.
31. Turn on the case sealer air supply and electrical power.
32. Verify correct operation by running test cartons through the case sealer.
Figure 2-34. Installing E-Stop Switch and Bracket
2-30 Copyright 1999, 3M IPC. All rights reserved.
Page 55
3M-Matic 800rf Case Sealer Adjustments
Table of Contents
3. Adjustments ...................................................................................................................................................3-1
3-1. Case Sealer Bed Height ..................................................................................................................... 3-1
3-2. Pneumatic Device Factory Set Points ................................................................................................3-2
3-3. Main Air Pressure Regulator ............................................................................................................. 3-4
3-4. Box Centering Pressure Regulator .....................................................................................................3-4
3-5. Side Belt Pressure Regulator ............................................................................................................. 3-5
3-6. Side Belts Closure Drive Chain .........................................................................................................3-5
3-7. Side Belts In/Out Rates ...................................................................................................................... 3-6
3-8. Side Belt Inner Limit ......................................................................................................................... 3-7
3-9. Side Belt Tension ...............................................................................................................................3-8
3-10. Motor Drive Belts, Upper and Lower ................................................................................................ 3-9
3-11. Drive Chain ...................................................................................................................................... 3-10
3-12. Safety Door Interlock....................................................................................................................... 3-10
3-13. Flap Folder Arm and Flap Folder Flow Controls - Speed Controls................................................. 3-11
3-14. Flap Folder Arm Reed Switch ......................................................................................................... 3-12
3-15. Cylinder Cushion Setting ................................................................................................................. 3-13
3-16. Paddle Pressure Regulator ............................................................................................................... 3-13
3-17. Counter-Balance Pressure Regulator ............................................................................................... 3-14
3-18. Case Top Sensitivity ........................................................................................................................3-14
3-19. Fork Cylinder Flow Controls - Speed Controls ............................................................................... 3-15
3-20. Infeed Box Stop-Gate Flow Control - Speed Control ...................................................................... 3-16
3-21. Box Centering Rails In/Out Rates ................................................................................................... 3-17
3-22. Upper Head Assembly Down/Up Rates........................................................................................... 3-18
3-23. Top Flap Compression Rollers ........................................................................................................ 3-19
3-24. Tape Web Alignment........................................................................................................................ 3-19
3-25. Tape Drum Friction Brake ............................................................................................................... 3-20
3-26. Tape Applying Mechanism Spring................................................................................................... 3-20
3-27. One-Way Tension Roller .................................................................................................................. 3-21
Copyright 1999, 3M IPC. All rights reserved. 3-i
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Adjustments 3M-Matic 800rf Case Sealer
3-28. Low Air Pressure Switch ................................................................................................................. 3-22
3-29. Overload Circuit Breaker ................................................................................................................. 3-23
3-30. Head Travel Limit Switch................................................................................................................ 3-23
3-ii Copyright 1999, 3M IPC. All rights reserved.
Page 57
3.
3M-Matic 800rf Case Sealer Adjustments
3. Adjustments
3-1. Case Sealer Bed Height
Specification
Adjust the case sealer bed height so that it is the same height as the conveyor line to which it is attached.
Adjustment
1. Raise and support the case sealer frame to allow adequate leg adjustment.
1. Using a 6 mm hex key wrench, loosen, but do not remove, two M8 x 16 mm socket-head cap screws in one leg. Refer to Figure 3-1.
Figure 3-1. Bed Height Adjustment
3. Using the height label as a guide, adjust the leg length to the desired conveyor bed height. Retighten the two screws to secure the leg.
4. Adjust the five remaining legs in the same way.
Copyright 1999, 3M IPC. All rights reserved. 3-1
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Adjustments 3M-Matic 800rf Case Sealer
3-2. Pneumatic Device Factory Set Points
Table 3-1 lists the factory set points for regulator pressure controls, Pneumatic Control Panel mounted speed controls, and cylinder mounted speed controls. The table also describes the location of each adjustment.
Table 3-1. Pneumatic Device Factory Set Points and Adjustment Locations
Regulator Pressure Controls
Regulator Pressure Controls Set Value Adjustment Location
Main Input Air Pressure 95 PSIG Air On/Off Valve/Filter/Regulator and gauge
assembly
Box Centering Pressure 50 PSIG Regulator  Underside of Pneumatic Control Panel,
extreme right
Side Belt Pressure 40 PSIG Regulator  Underside of Pneumatic Control Panel,
second from extreme right
Paddle Pressure 7 PSIG Regulator  Underside of Pneumatic Control Panel,
third from extreme right
Box Counter-Balance Pressure 40 PSIG Regulator  Underside of Pneumatic Control Panel,
extreme left
To increase air pressure, turn the regulator knob clockwise (CW). To decrease air pressure, turn the regulator knob counterclockwise (CCW). There is an air pressure gauge label located on the front of the Pneumatic Control Panel referencing the gauges located on the top of the panel.
Pneumatic Control Panel Mounted Speed Controls
Air Rate Exhaust Restriction Controls (Speed Controls) Set Value Adjustment Location
Centering Arms OUT 6 turns CCW Upper (OUT) of two restriction controls  Top of
Pneumatic Control Panel, extreme right
Centering Arms IN 11 turns CCW Lower (IN) of two restriction controls  Top of
Pneumatic Control Panel, extreme right
Side Belts OUT 9 turns CCW Upper (OUT) of two restriction controls  Top of
Pneumatic Control Panel, center
Side Belts IN 6 turns CCW Lower (IN) of two restriction controls  Top of
Pneumatic Control Panel, center
Head DOWN 11 turns CCW Lower (DOWN) of two restriction controls  Top of
Pneumatic Control Panel, extreme left
Head UP 15 turns CCW Upper (UP) of two restriction controls  Top of
Pneumatic Control Panel, extreme left
All adjustments are made from the fully closed position. Loosen the locking nut and turn the brass knurled screw fully CW, then turn the screw CCW the number of turns specified above.
3-2 Copyright 1999, 3M IPC. All rights reserved.
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3M-Matic 800rf Case Sealer Adjustments
Table 3-1. Pneumatic Device Factory Set Points and Adjustment Locations (Continued)
Cylinder Mounted Speed Controls
Air Rate Exhaust Restriction Controls (Speed Controls) Set Value Adjustment Location
Infeed Gate UP 3/4 of turn CCW On Gate Cylinder  Underside of entrance end of
case sealer Infeed Gate DOWN Not applicable No control device is present Fork UP 12 turns CCW On Fork Cylinder cap end  Remove center
conveyor bed to expose cylinder Fork DOWN 13 turns CCW On Fork Cylinder rod end  Remove center
conveyor bed to expose cylinder Folder Arm EXTEND 11 turns CCW On Folder Arm Cylinder rod end  Through access
holes in Arm Assembly cover Folder Arm RETRACT 5 turns CCW On Folder Arm Cylinder cap end  Through access
holes in Arm Assembly cover Rear Flap Folder EXTEND 16 turns CCW On Rear Flap Folder Cylinder rod end  Through
access holes in Folder Assembly cover Rear Flap Folder RETRACT 10 turns CCW On Rear Flap Folder Cylinder cap end  Through
access holes in Folder Assembly cover All adjustments are made from the fully closed position. Use a standard straight edge screwdriver or loosen the
knurled ring nut and adjust the thumbscrew fully CW, then turn the thumbscrew CCW the number of turns specified above.
Copyright 1999, 3M IPC. All rights reserved. 3-3
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Adjustments 3M-Matic 800rf Case Sealer
3-3. Main Air Pressure Regulator
Specification
The case sealer requires a compressed air supply of 75  140 PSIG [5.2  9.5 BAR] 7.0 SCFM [11.89 m cycle rate.
The optimum operating set point on the gauge is 95  100 PSIG.
Adjustment
If the pressure is lower than that specified, check the input pressure at the source. If the source pressure is lower than 75 PSIG [5.2 BAR], there is not enough pressure to operate the case sealer properly. Also note that the inner diameter and length of the incoming air supply can affect final air pressure and recovery rate SCFM.
If the pressure at the source is between 75  140 PSIG (this is the maximum pressure shown on the gauge), make the following adjustment.
3
/h, 21oC, 101 kPa] maximum at maximum
ü Note
3-4 . Box Centering Pressure Regulator
Specification
The Box Centering Pressure Regulator should be set to permit positive centering of the various weights of boxes the customer is using. Set the pressure to provide sufficient centering force without creating excessive drag. Keep in mind the maximum box weight capacity (filled) is 65 pounds, and the minimum weight must be sufficient to hold the case on the conveyor bed with the bottom flaps flat.
Adjustment
1. Refer to Figure 3-3. Adjust the Box Centering Pressure Regulator on the underside of the Pneumatic Control Panel (CW  increases pressure, CCW  decreases pressure). Observe the Box Centering Pressure Gauge on the top of the panel.
1. Refer to Figure 3-2. Adjust the Main Air Pressure Regulator to read 95  100 PSIG on the gauge (CW  increases pressure, CCW  decreases pressure).
Figure 3-3. Box Centering Pressure Regulator
Adjustment
Figure 3-2. Main Air Pressure Regulator
Adjustment
3-4 Copyright 1999, 3M IPC. All rights reserved.
Page 61
3M-Matic 800rf Case Sealer Adjustments
3-5. Side Belt Pressure Regulator
Specification
The side belt pressure should be set so that cases are driven smoothly through the sealing process by the belts without the cases being deformed by excessive side pressure.
!
Caution
Excessive belt wear occurs when side belts are allowed to slip on the boxes.
Adjustment
1. Refer to Figure 3-4. Adjust the Side Belt Pressure Regulator on the underside of the Pneumatic Control Panel so that the gauge reads 40 PSIG with the Main Air Pressure Regulator set correctly (CW  increases pressure, CCW  decreases pressure). Observe the Side Belt Pressure Gauge on the top of the panel.
ü Note
Air pressure can be reduced for light-weight cases. Adjust side belt pressure so that the cases are cen­tered and are driven smoothly.
3-6. Side Belts Closure Drive Chain
This is not a routine adjustment. Normally, it is necessary only after major disassembly or repair of related components.
Specification
Adjust the side belts closure drive chain so that the side drive belts are equally spaced from the center of the case sealer bed at their outermost position. The tension of the drive chain must be tight enough to ensure smooth inward drive.
Adjustment
1. Remove the case sealer bed plates as described in Section 4-6, Case Sealer Bed Plates.
2. Refer to Figure 3-5. Loosen the lock nuts on the drive chain.
3. Turn the adjustment bolts to obtain the proper position and tension.
ü Note
If correct belt position cannot be obtained by means of the adjustment bolts, remove the chain and reposition it.
Figure 3-5. Side Belts Closure Drive Chain
Adjustment
4. Reinstall all parts removed in step 1.
Figure 3-4. Side Belt Pressure Regulator
Adjustment
Copyright 1999, 3M IPC. All rights reserved. 3-5
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Adjustments 3M-Matic 800rf Case Sealer
3-7. Side Belts In/Out Rates
This is not a routine adjustment. Normally, it is necessary only after major disassembly or repair of related components.
Specification
Adjust the Side Belt IN/OUT speed flow controls to allow the side belts to move to the center of the case sealer bed at approximately the same speed as they return to their outer position. The rate of closure (IN) is the primary measure of a good speed. It must be slow enough to help center but not bounce a small box, and not so slow as to reduce the overall produc­tion rate.
ü Note
If the side belts do not return (move OUT) from the center of the case sealer bed when no box is present, refer to Section 3-8, Side Belt Inner Limit, before proceeding.
Adjustment
1. Pass an average size box through the case sealer.
2. Observe the rates of side belt closure and return.
3. Adjust the Side Belt IN/OUT speed control valves, as shown in Figure 3-6 (CW  decreases speed, CCW  increases speed). These controls are located on the top of the Pneumatic Control Panel.
ü Note
If there is any confusion as to where to set the speed control valves, turn the valves fully CW and then turn the OUT control 9 full turns CCW and turn the IN control 6 full turns CCW. Refer to Table 3-1, Pneumatic Device Factory Set Points and Adjust­ment Locations.
Figure 3-6. Side Belt IN/OUT Rate Adjustment
3-6 Copyright 1999, 3M IPC. All rights reserved.
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3M-Matic 800rf Case Sealer Adjustments
3-8. Side Belt Inner Limit
This is not a routine adjustment. Normally, it is necessary only after major disassembly or repair of related components.
Specification
With no box in the case sealer, adjust the side drive belt assembly inner limit reed switch so that the assembly closes to the center of the case sealer bed. All side drive belt motors stop and the assembly returns to its outermost position.
Adjustment
1. Raise the upper head assembly to its uppermost position by setting the mode selector switch to RANDOM and pressing the RESET button.
2. Turn off the main air valve and the electrical disconnect switch.
3. Refer to Section 4-6, Case Sealer Bed Plates, and remove the center roller assembly.
6. If the side drive belt assembly does not move to its outermost position, press the STOP button. The assembly will move out so the following adjustment can be made.
7. Refer to Figure 3-7. Using a 2 mm hex wrench loosen the screws on the reed switch. Move the switch to the right in increments until, when tested as described earlier, the assembly returns to its outermost position.
8. Replace the center roller assembly.
4. Turn on the main air valve and the electrical disconnect switch. Press the RESET button then the START
5. Block the light path from PC1 and then PC3. Blocking the light path of PC3 causes the side drive belt assembly to move in to the center. This closes the limit reed switch on the assembly movement cylinder. The switch closing initiates an input to the Programmable Controller result­ing in a fault condition, which causes the assem­bly to return to its outermost position.
Figure 3-7. Side Belt Inner Limit Adjustment
Copyright 1999, 3M IPC. All rights reserved. 3-7
Page 64
Adjustments 3M-Matic 800rf Case Sealer
3-9. Side Belt Tension
This is not a routine adjustment. Normally, it is necessary only after major disassembly or repair of related components.
Specification
Adjust the tension of the side belts so that the cases move through the machine positively and the belts wrap tightly around the surface of the idler pulleys at each end of the frame.
Warning
Warning!
Turn all electrical power off and disconnect the power cord from the power outlet before doing this adjustment.
Measurement
1. Turn the case sealer off and disconnect the power cord.
!
Caution
In the following adjustment, be sure to adjust BOTH belt tension assemblies.
1. Remove the side drive belt assembly. (Refer to Section 4-3, Side Drive Belt Assembly.)
2. Loosen the lock nuts on both the upper and lower belt tension assemblies. Refer to Figure 3-9.
2. Use a force gauge to pull each side belt outward 1 inch [25.4 mm], near its mid-span. The gauge should read 7 lb. [3.2 kg]. Refer to Figure 3-8.
Figure 3-8. Side Belt Tension Test Adjustment
Figure 3-9. Side Belt Tension Adjustment
3. Turn the adjustment screws equally on both the upper and lower belt tension assemblies. Turn the screws CW to decrease belt tension; CCW to increase belt tension.
ü Note
If you decrease belt tension, be sure to push the idler (end) pulley inward, toward the adjustment screws, before tightening the lock nuts.
4. Tighten both the upper and lower lock nuts.
3-8 Copyright 1999, 3M IPC. All rights reserved.
Page 65
3M-Matic 800rf Case Sealer Adjustments
3-10. Motor Drive Belts, Upper and Lower
This is not a routine adjustment. Normally, it is necessary only after major disassembly or repair of related components.
Specification
Adjust the motor drive belts to maintain proper belt tension.
Adjustment
Warning!
Warning
Turn the main air supply and electrical power off before making this adjustment.
1. Remove the cover from the side drive belt assembly. Refer to Figure 3-10.
5. Loosen, but do not remove, the four screws securing the motor to its base. Refer to Figure 3-11.
Figure 3-10. Side Belt Removal
2. Unplug the drive motor using the quick-disconnect plug.
3. Release side belt tension. Refer to Section 3-9, Side Belt Tension.
4. Remove the side drive belt.
Figure 3-11. Motor Drive Belts Adjustment
6. Loosen, but do not remove, the lower self-locking nut on the jockey pulley.
7. Move the jockey pulley toward the belt to tighten the drive motor lower belt. Secure the lower self-locking nut on the jockey pulley.
8. Move the drive motor toward the exit end of the case sealer to tighten the drive motor upper belt. Tighten the four motor mounting screws.
9. Reinstall the side drive belt and adjust the belt tension as described in Section 3-9, Side Belt Tension.
10. Reinstall the belt cover and reconnect the drive motor power plug.
Copyright 1999, 3M IPC. All rights reserved. 3-9
Page 66
Adjustments 3M-Matic 800rf Case Sealer
3-11. Drive Chain
This is not a routine adjustment. Normally, it is necessary only after major disassembly or repair of related components.
Specification
There is no exact chain tension specification. Adjust the chain so that it is just tight enough to drive reliably without slack.
Adjustment
Loosen three bolts, adjust the chain, and retighten the bolts. Refer to Figure 3-12.
ü Note
If you adjust the drive chain, it is also necessary to adjust the upper and lower motor drive belts. Refer to Section 3-10, Motor Drive Belts, Upper and Lower.
3-12. Safety Door Interlock
This is not a routine adjustment. Normally, it is necessary only after major disassembly or repair of related components.
Specification
Adjust each door interlock switch so that it de­actuates when the safety door is fully closed and actuates when the safety door is opened slightly.
Adjustment
1. Check that all four doors are aligned flush with the door frames, and that each switch actuator mounted on the door fits securely into the red interlock switch.
2. Loosen the two screws securing the interlock switch to the door frame. Refer to Figure 3-13.
3. With the door fully closed, hold the switch actuator and interlock switch firmly together and tighten the screws.
Figure 3-12. Drive Chain Adjustment
4. Test the door interlock with the electrical power on.
a. Open the door. The red E-STOP/SLIDING
DOOR indicator lights on the Electrical Control Panel.
b. Close the door. The indicator turns off.
Figure 3-13. Safety Door Interlock Adjustment
3-10 Copyright 1999, 3M IPC. All rights reserved.
Page 67
3M-Matic 800rf Case Sealer Adjustments
3-13. Flap Folder Arm and Flap Folder Flow
Controls - Speed Controls
This is not a routine adjustment. Normally, it is necessary only after major disassembly or repair of related components.
Specification
Adjust the cylinder-mounted speed flow controls for optimum stroke operation. Consider a smooth cylinder extension and retraction without banging at the end of either motion.
Adjustment
The Flap Folder Arm Cylinder and the Flap Folder Cylinder both have speed flow controls located at each end of the cylinders; one control at the cap end, and one control at the rod end. Refer to Figure 3-14.
1. Adjust the Flap Folder Arm Cylinder speed flow controls (CW  decreases speed, CCW  increases speed).
a. Adjust the cap end to control the speed of the
retract (down) motion.
b. Adjust the rod end to control the speed of the
extend (up) motion.
2. Adjust the Flap Folder Cylinder speed flow controls (CW  decreases speed, CCW  increases speed).
a. Adjust the cap end to control the speed of the
retract (out to fold flap) motion.
b. Adjust the rod end to control the speed of the
extend (in to home position) motion.
ü Note
If there is any confusion as to where to set the speed flow controls, turn the adjusting screws fully CW. Flap Folder Arm Cylinder  turn the cap-end screw 5 full turns CCW and turn the rod-end screw 11 full turns CCW. Flap Folder Cylinder  turn the cap-end screw 10 full turns CCW and turn the rod-end screw 16 full turns CCW. Refer to Table 3-1, Pneumatic Device Factory Set Points and Adjustment Locations (Cylinder Mounted Speed Controls).
Figure 3-14. Flap Folder Arm and Flap Folder
Speed Control Adjustments
Copyright 1999, 3M IPC. All rights reserved. 3-11
Page 68
Adjustments 3M-Matic 800rf Case Sealer
3-14. Flap Folder Arm Reed Switch
This is not a routine adjustment. Normally, it is necessary only after major disassembly or repair of related components.
Specification
The factory set position of the circular bracket that holds the reed switch to the Flap Folder Arm Cylinder wall is approximately 2.5 inches from the cap end of the cylinder. When the switch signals an output, the Flap Folder Cylinder activates and the Flap Folder moves downward, folding the rear flap of the box inward.
Adjustment
1. Observe when the Flap Folder activates. It should begin to move downward when the Flap Folder Arm is about midway between fully extended and fully retracted. Refer to Figure 3-
15.
2. Loosen the screw securing the switch bracket and move the reed switch and bracket toward the rod end of the cylinder to activate the Flap Folder sooner. Move the switch and bracket toward the cap end of the cylinder to activate the Flap Folder later.
3. When the reed switch is set correctly, tighten the screw securing the switch bracket. Avoid switch movement while doing this.
Figure 3-15. Flap Folder Arm Reed Switch Adjustment
3-12 Copyright 1999, 3M IPC. All rights reserved.
Page 69
3M-Matic 800rf Case Sealer Adjustments
3-15. Cylinder Cushion Setting
ü Note
This is a generic approach to adjusting the cylinder cushion settings for all cylinders used in the 800rf Case Sealer.
This is not a routine adjustment. Normally, it is not necessary to adjust the cylinder cushion settings unless a new cylinder is installed to replace an original component.
Specification
Adjust cushion settings so that the cylinder does not bottom out hard at the end travel of its stroke.
Adjustment
Set the cylinder cushions for the setting that allows proper operation as described in the above specifica­tion. Typically, these are factory set and do not need to be adjusted.
3-16. Paddle Pressure Regulator
Specification
The Paddle Pressure Regulator should be set so that as the paddle makes contact with the top of the carton when the upper head assembly descends, it does not overtravel and deform the carton.
Adjustment
1. Refer to Figure 3-17. Adjust the Paddle Pressure Regulator on the underside of the Pneumatic Control Panel so the gauge reads 7 PSIG with the Main Air Pressure Regulator set correctly (CW  increases pressure, CCW  decreases pressure). Observe the Paddle Pressure Gauge on the top of the panel.
ü Note
Too much pressure results in excessive drag on the top of the carton or deforming of the carton.
1. Refer to Figure 3-16 for adjusting screw loca­tions. This is a generic view for all cylinders used in the 800rf Case Sealer.
2. Turn the adjusting screws fully CW (closed).
3. Adjust by turning the screws 1/8 to 1/4 turn CCW.
Figure 3-16. Cushion Adjusting Screw Locations
Figure 3-17. Paddle Pressure Regulator
Adjustment
Copyright 1999, 3M IPC. All rights reserved. 3-13
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Adjustments 3M-Matic 800rf Case Sealer
3-17. Counter-Balance Pressure Regulator
Specification
The Counter-Balance Pressure Regulator should be set so the upper head assembly comes to a stop between 0 and 1/8 inch from the top of the carton.
Adjustment
1. Refer to Figure 3-18. Adjust the Counter-Balance Pressure Regulator on the underside of the Pneumatic Control Panel so the gauge reads 40 PSIG with the Main Air Pressure Regulator set correctly (CW  increases pressure, CCW  decreases pressure). Observe the Counter-Balance Pressure Gauge on the top of the panel. Higher gauge pressure means more
pressure on top of the carton.
1. Observe production and examine cartons that have been run.
ü Note
Too little pressure results in tape being cut improp­erly or not being cut at all (head too high above box). Too much pressure results in dragging and scoring on the top of the cartons (head too low).
3-18. Case Top Sensitivity
Specification
Adjust the case top sense reed switch so that the head lowers just enough to ensure that the side flaps are held securely against the top of the case during the taping operation. The downward pressure of the top taping head must not be great enough to distort the box in any way.
Adjustment
1. Slide the safety door fully open to gain access to the reed switch.
2. Loosen the set screw securing the reed switch and move the switch toward the infeed end of the case sealer to decrease sensitivity (increase pressure on the top of the case). Move the switch toward the exit end of the case sealer to increase sensitivity (decrease pressure on the top of the box). Refer to Figure 3-19. (The switch is located inside the paddle assembly.)
ü Note
The normal position for the case top sense reed switch is almost fully toward the infeed end of the case sealer.
Figure 3-18. Counter-Balance Pressure Regulator
Adjustment
3. When the case top sensitivity is correct, tighten the set screw securing the reed switch. Avoid switch movement while doing this.
Figure 3-19. Case Top Sensitivity Adjustment
3-14 Copyright 1999, 3M IPC. All rights reserved.
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3M-Matic 800rf Case Sealer Adjustments
3-19. Fork Lift Flow Controls-Speed
Controls
These cylinder-mounted speed flow controls are factory set and normally do not need adjusting unless related components are replaced.
Specification
Adjust the Fork Cylinder speed flow controls so that:
1. The fork automatically moves down to its hori­zontal position before case movement forces it down.
2. The fork returns to its upright vertical position before the side belts begin to move inward to receive the next carton.
3. Fork movement occurs without banging or rebound.
Adjustment
Before making any adjustments on these speed flow controls, the Main Air Pressure Regulator must be set correctly.
ü Note
If there is any confusion as to where to set the speed flow controls, turn the adjusting screws fully CW, then turn the cap-end screw 12 full turns CCW and turn the rod-end screw 13 full turns CCW. Refer to Table 3-1, Pneumatic Device Factory Set Points and Adjustment Locations (Cylinder Mounted Speed Controls).
Figure 3-20. Fork Speed Control Adjustment
1. Remove the center conveyor bed as described in Section 4-6, Case Sealer Bed Plates.
2. Refer to Figure 3-20. Adjust the Fork Cylinder speed flow controls (CW  decreases speed, CCW  increases speed).
a. Adjust the cap end to control the speed of the
retract (fork down) motion.
b. Adjust the rod end to control the speed of the
extend (fork up) motion.
3. Replace the center conveyor bed.
Copyright 1999, 3M IPC. All rights reserved. 3-15
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Adjustments 3M-Matic 800rf Case Sealer
3-20. Infeed Box Stop-Gate Flow Control-
Speed Control
This cylinder-mounted speed flow control is factory set and normally does not need adjusting unless the cylinder is replaced.
Specification
Adjust the Infeed Box Stop-Gate Cylinder speed flow control for optimum stroke operation. Consider a smooth cylinder extension without banging or rebound.
Adjustment
1. Access the Infeed Box Stop-Gate Cylinder from the underside of the infeed end of the case sealer.
2. Adjust the speed flow control (CW  decreases speed, CCW  increases speed).
ü Note
If there is any confusion as to where to set the speed flow control, turn the adjusting screw fully CW, then turn the screw 3/4 of a turn CCW. Refer to Table 3-1, Pneumatic Device Factory Set Points and Adjust­ment Locations (Cylinder Mounted Speed Controls).
3-16 Copyright 1999, 3M IPC. All rights reserved.
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3M-Matic 800rf Case Sealer Adjustments
3-21. Box Centering Rails In/Out Rates
This is not a routine adjustment. Normally, it is necessary only after major disassembly or repair of related components.
Specification
Adjust the Box Centering IN/OUT speed flow controls to allow the centering rails to close (move IN) and center the carton, then release (move OUT) and open to their home position at approximately the same speed. The rate of closure (IN) is the primary measure of a good speed. It must be slow enough to center but not bounce a small box, and not so slow as to reduce the overall production rate.
Adjustment
1. Pass some average size boxes through the case sealer.
2. Observe the speed of the centering rails closure (IN) and return (OUT).
3. Adjust the Box Centering IN/OUT speed control valves, as shown in Figure 3-21 (CW  decreases speed, CCW  increases speed). These controls are located on the top of the Pneumatic Control Panel, extreme right.
ü Note
If there is any confusion as to where to set the speed control valves, turn the valves fully CW and then turn the OUT control 6 full turns CCW and turn the IN control 11 full turns CCW. Refer to Table 3-1, Pneumatic Device Factory Set Points and Adjust­ment Locations (Pneumatic Control Panel Mounted Speed Controls).
Figure 3-21. Box Centering Rails IN/OUT Rate Adjustment
Copyright 1999, 3M IPC. All rights reserved. 3-17
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Adjustments 3M-Matic 800rf Case Sealer
3-22. Upper Head Assembly Down/Up Rates
This is not a routine adjustment. Normally, it is necessary only after major disassembly or repair of related components.
Specification
Adjust the Upper Head DOWN/UP speed flow controls to allow the Upper Head Assembly to descend and raise smoothly and without banging, causing undue wear to the Upper Head Assembly and its cylinders.
Adjustment
1. Pass some average size boxes through the case sealer.
2. Observe the speed at which the Upper Head Assembly descends (DOWN) and raises (UP).
3. Adjust the Upper Head Assembly speed control valves, as shown in Figure 3-22 (CW  decreases speed, CCW  increases speed). These controls are located on the top of the Pneumatic Control Panel, extreme left.
ü Note
If there is any confusion as to where to set the speed control valves, turn the valves fully CW and then turn the DOWN control 11 full turns CCW and turn the UP control 15 full turns CCW. Refer to Table 3­1, Pneumatic Device Factory Set Points and Adjust­ment Locations (Pneumatic Control Panel Mounted Speed Controls).
Figure 3-22. Upper Head Assembly DOWN/UP Rate Adjustment
3-18 Copyright 1999, 3M IPC. All rights reserved.
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3M-Matic 800rf Case Sealer Adjustments
3-23. Top Flap Compression Rollers
Specification
Adjust the top flap compression rollers to hold the top flaps of the case together during the taping process. The flaps should not overlap or have space between them after the taping process.
Adjustment
1. Adjust all compression rollers inward to hold the top of the box more securely. Refer to Figure 3-
23.
2. Adjust all compression rollers outward if the box binds.
3-24. Tape Web Alignment
Specification
Position the tape drum shaft so that the tape is centered on the centerline of the taping head.
Adjustment
The tape drum assembly on each taping head is pre­set to accommodate 2 inch [48 mm] wide tape, but is adjustable to handle narrower tapes. To center the tape width on the centerline of the taping head, make the adjustment as follows:
1. Use an adjustable wrench or a 25 mm open-end wrench to loosen the locking hex nut on the tape drum shaft behind the tape drum bracket. Refer to Figure 3-24.
2. Use a 5 mm hex key wrench to turn the tape drum shaft CW (in) or CCW (out) to center the tape web on the centerline of the taping head.
Figure 3-23. Top Flap Compression Rollers
Adjustment
Figure 3-24. Tape Web Alignment Adjustment
3. Tighten the locking hex nut to secure the shaft in this new position.
Copyright 1999, 3M IPC. All rights reserved. 3-19
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Adjustments 3M-Matic 800rf Case Sealer
3-25. Tape Drum Friction Brake
Specification
Adjust the tape drum friction brake to prevent exces­sive tape overtravel caused by a flywheel effect.
Adjustment
1. Refer to Figure 3-25. Turn the self-locking nut on the shaft to adjust the braking force (CW  increases braking force, CCW  decreases braking force).
2. Adjust the friction brake for the minimum braking force that prevents excessive overtravel.
ü Note
Excessive braking force causes poor tape application and may lead to tape tabbing on the trailing tape leg.
3-26. Tape Applying Mechanism Spring
Specification
Adjust the position of the tape applying mechanism spring so there is sufficient pressure to seal the box, and after sealing the box, the tape buffing roller returns to its rest position.
Adjustment
1. To gain access to the spring, remove the taping head cover (four mounting screws).
2. Increase or decrease the pressure applied by the tape applying mechanism spring by removing the end loop from the spring holder and moving it to another hole. Refer to Figure 3-26.
3. If a tape gap appears on the trailing surface of the box, increase the spring pressure.
4. If the front of the box is being crushed by the applying roller, decrease the spring pressure.
Figure 3-26. Tape Applying Mechanism Spring
Adjustment
Figure 3-25. Tape Drum Friction Brake
Adjustment
3-20 Copyright 1999, 3M IPC. All rights reserved.
5. Replace the taping head cover (four mounting screws).
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3M-Matic 800rf Case Sealer Adjustments
3-27. One-Way Tension Roller
Specification
Adjust the one-way tension roller so that it slips under a tangential force of 1 to 2 lbs. [0.5 to
0.9 kg]. Refer to Figure 3-27.
Figure 3-27. One-Way Tension Roller Adjustment
Measurement
1. Wrap a cord or small strap (non-adhesive) 4 to 6 turns around the tension roller.
2. Attach a spring scale to the end of the cord or strap.
3. Pull the spring gauge until the one-way tension roller slips. The spring gauge should read 1 to 2 lbs [0.5 to 0.9 kg] when slippage occurs.
Adjustment
Turn the self-locking adjusting nut to adjust the holding force (CW  increases holding force, CCW  decreases holding force).
Copyright 1999, 3M IPC. All rights reserved. 3-21
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Adjustments 3M-Matic 800rf Case Sealer
3-28. Low Air Pressure Switch
Specification
Adjust the Low Air Pressure Switch so the case sealer shuts down if the main air pressure drops below 50 PSIG and a box feed is attempted.
ü Note
All adjustments to the Low Air Pressure Switch must be made with the Main Air On/Off Valve in the Off position.
Measurement
1. Set the Main Air Pressure Regulator Gauge to read 50 PSIG.
2. With the electrical power and air pressure con­nected, start the machine by pressing the RESET button and then the START button.
The case sealer side drive motors should start and the red RESET lamp should light.
NOT
4. Connect the electrical power and air pressure, turn the On/Off Air Valve to the On position, and set the Main Air Pressure Regulator Gauge to read 50 PSIG.
5. Press the RESET button and then the START button. If the case sealer motors do not start, the switch is set properly.
6. If the case sealer motors start at 50 PSIG, the Low Air Pressure Switch is set too high and adjust­ment is necessary.
a. Turn the Main Air On/Off Valve to the Off
position.
b. Turn the Low Air Pressure Switch adjusting
screw CCW by 1/2-turn increments and repeat steps 4 and 5 until the motors do not start.
7. Reset the Main Air Pressure Regulator Gauge to read 95 PSIG and perform a final operational test by running a carton through the case sealer.
3. Set the Main Air Pressure Regulator Gauge to read 95 PSIG.
4. Start the machine by pressing the RESET button and then the START button.
The case sealer should operate properly (RUN light is on, motors are on, and side belts are rotating). You should be able to convey a carton through the machine and have it successfully seal the top and bottom seams of the carton.
Adjustment
1. Turn the Main Air On/Off Valve to the Off position.
2. Locate the adjusting screw on top of the Low Air Pressure Switch and turn it fully CCW until it stops, being careful not to damage the adjusting screw. Refer to Figure 3-28.
3. Preset the adjusting screw by turning it 9 full turns CW.
Figure 3-28. Low Air Pressure Switch Adjustment
3-22 Copyright 1999, 3M IPC. All rights reserved.
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3M-Matic 800rf Case Sealer Adjustments
3-29. Overload Circuit Breaker
Specification
Adjust the setting screw on the Overload Circuit Breaker to the 1.4 Amp setting.
Adjustment
Use a Phillips-head screwdriver to set the alignment mark to the 1.4 Amp setting. Refer to Figure 3-29.
3-30. Head Travel Limit Switch
Specification
Adjust the Head Travel Limit Switch located on the rear head raising cylinder so when the head is at the rest position, it is approximately 3 inches above the highest box being run.
Adjustment
1. Loosen the two securing screws. Refer to Figure 3-30.
2. Move the switch up or down as required.
3. Tighten the screws.
4. Check the head rest position.
5. Repeat steps 1 through 4 until the head rest position is approximately 3 inches above the highest box being run.
Figure 3-29. Overload Circuit Breaker
Adjustment
Figure 3-30. Head Travel Limit Switch
Adjustment
Copyright 1999, 3M IPC. All rights reserved. 3-23
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3M-Matic 800rf Case Sealer Disassembly/Reassembly
Table of Contents
4. Disassembly/Reassembly ..............................................................................................................................4-1
4-1. General ............................................................................................................................................... 4-1
4-2. Format ................................................................................................................................................4-1
4-3. Side Drive Belt Assembly .................................................................................................................. 4-2
4-4. Side Drive Belt................................................................................................................................... 4-3
4-5. Motor Drive Belts, Upper and Lower ................................................................................................ 4-4
4-6. Case Sealer Bed Plates....................................................................................................................... 4-6
4-7. Fork Cylinder .....................................................................................................................................4-7
4-8. Side Drive Belts Cylinder .................................................................................................................. 4-7
4-9. Flap Folder Cylinder ..........................................................................................................................4-8
4-10. Flap Folder Arm Cylinder.................................................................................................................. 4-8
4-11. Knife Replacement, Upper Taping Head ........................................................................................... 4-9
4-12. Knife Replacement, Lower Taping Head .........................................................................................4-10
4-13. Belt Drive Pulley Assembly Ribbed Rings ...................................................................................... 4-10
4-14. Infeed Rollers ...................................................................................................................................4-12
4-15. Overload Circuit Breaker ................................................................................................................. 4-14
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3M-Matic 800rf Case Sealer Disassembly/Reassembly
4. Disassembly/Reassembly
4-1. General
This section provides instructions for removing components and major assemblies from the Model 800rf Type 39800 Case Sealer. Disassembly should be done only to replace a faulty part. Be sure the component is out of tolerance as defined in Section 3, Adjustments, before assuming it is worn or defective.
4-2. Format
Many of the disassembly procedures in this section are illustrated views with a minimum of supporting text. The order of disassembly is indicated by circled numbers with 1 being the first step, 2 the second step, and so on. Reassembly is done in the reverse order of disassembly.
Carefully review and understand each procedure before the disassembly of any component. Often, reference to the exploded view in Section 7, Illustrated Parts Breakdown, aids disassembly and subsequent reassembly.
Warning!
Turn off the main air supply and electrical
power before removing any components.
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Disassembly/Reassembly 3M-Matic 800rf Case Sealer
4-3. Side Drive Belt Assembly
Warning!
Turn off the main air supply and electrical
power before removing any components.
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3M-Matic 800rf Case Sealer Disassembly/Reassembly
4-4. Side Drive Belt
Warning!
Warning
Turn off the main air supply and electrical
power before removing any components.
1. Remove the side drive belt assembly using Procedure 4-3 in this section.
ü Note
If the side drive belt being removed is without pin and lacing, the belt must be cut to remove it. A replacement side drive belt with pin and lacing is needed to reassemble the unit.
5. Install the new drive belt.
6. After installing the new belt, adjust the side drive belt tension. Refer to Side Belt Tension in Section 3.
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Disassembly/Reassembly 3M-Matic 800rf Case Sealer
4-5. M
Turn off the main air supply and electrical
power before removing any components.
A gear puller is needed to complete this procedure. Make sure a gear puller is available before begin­ning this procedure.
1. Remove the side drive belt assembly using
2. Remove the side drive belt using Procedure 4-4 in
3. Remove the self-locking nut and the washer from
4. Remove the bolt and washer from the bottom of
5. Remove the M22 nut from the bottom of the
otor Drive Belts, Upper and Lower
Warning!
ü Note
Procedure 4-3 in this section.
this section.
the top of the wrap pulley assembly [43].
the rod. Slide the rod out of the threaded sleeve.
threaded sleeve.
10. Remove the chain [75] by disconnecting the removable link.
11. Remove the two standoffs on which the chain cover [76] is mounted.
12. Remove the screw and washer holding the sprocket [33] on the bottom of the drive pulley assembly [27].
13. Remove the 3/8-inch keyed sprocket [33], using a gear puller, and being careful not to lose the key.
14. Remove the three (3) hex-head bolts and washers holding the drive pulley assembly [27].
15. Remove the drive pulley assembly [27].
16. Remove the six (6) hex head bolts which hold the two halves of the side drive belt assembly to­gether from the bottom of the assembly.
17. Lift the lower half of the side drive belt assem­bly and move it aside from the upper half, pivoting on the belt drive pulley assembly [15] shaft.
18. Remove the wrap pulley assembly [43].
6. Loosen but do not remove the self-locking nut on the jockey pulley assembly [35].
7. Remove the hex-head screw and the washer from the bottom of the wrap pulley assembly [43].
8. Remove the nut and washer from the bottom of the idler roller assembly [51].
9. Remove the two screws holding the chain cover [76] in place and remove the chain cover.
19. Remove the timing belt(s) to be replaced.
20. To reassemble and reinstall the side drive belt assembly, perform steps 1 through 19 of this procedure in reverse order.
21. When the side drive belt assembly has been reassembled and reinstalled, perform the follow­ing adjustment procedures described in Section 3.
Motor Drive Belts, Upper and Lower
Side Belt Tension
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3M-Matic 800rf Case Sealer Disassembly/Reassembly
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Disassembly/Reassembly 3M-Matic 800rf Case Sealer
4-6. Case Sealer Bed Plates
Warning!
Turn off the main air supply and electrical
power before removing any components.
1. Remove the side drive belt assembly using Procedure 4-3 in this section.
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3M-Matic 800rf Case Sealer Disassembly/Reassembly
4-7. Fork Cylinder
Warning!
ng
Turn off the main air supply and electrical
power before removing any components.
1. Remove the case sealer bed plates using Procedures 4-3 and 4-6 in this section.
4-8.
1. Remove the case sealer bed plates using
Side Drive Belts Cylinder
Warning!
g
Turn off the main air supply and electrical
power before removing any components.
Procedures 4-3 and 4-6 in this section.
5. Remove the associated air lines and hardware from the cylinder.
6. Reassembly requires adjustment of fork speed. Refer to Fork Cylinder Flow Controls  Speed Controls in Section 3.
2. Remove the associated air lines and hardware from the cylinder.
Before removing the limit switch (sensor) attached to the cylinder housing, note the switch position on the cylinder so you can install the switch at the same position on the replacement cylinder. The position of the limit switch affects cylinder extension, timing, etc.
3. Reassembly requires adjustment of side drive belt pressure and side drive belts closure/retract rates. Refer to Side Belt Pressure Regulator and Side Belts In/Out Rates in Section 3.
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Disassembly/Reassembly 3M-Matic 800rf Case Sealer
4-9.
Steps 1 through 3 on the figure below refer to removal of the Flap Folder Cylinder.
1. Remove associated hardware, air lines, and flow
2. If a flow control is replaced, adjust the new
Flap Folder Cylinder
Warning!
Turn off the main air supply and electrical
power before removing any components.
control valves.
flow control to match the one removed. Refer to Flap Folder Arm and Flap Folder Flow Controls  Speed Controls in Section 3.
4-10. Flap Folder Arm Cylinder
Warning!
Turn off the main air supply and electrical
power before removing any components.
Steps 6 through 8 on the figure below refer to removal of the Flap Folder Arm Cylinder.
1. Remove associated hardware, air lines, and flow controls. Note the position of the limit switch (sensor) attached to the cylinder housing so you can install the switch at the same position on the replacement cylinder. The position of the limit switch affects cylinder extension, timing, etc.
2. If a flow control is replaced, adjust the new flow control to match the one removed. Refer to Flap Folder Arm and Flap Folder Flow Controls  Speed Controls in Section 3.
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4-11. Knife Replacement, Upper Taping
Head
Warning!
The Tape Cut-Off Knife is very sharp. To avoid personal injury, handle the knife with special care. Also, disconnect the power before starting this procedure.
1. Apply air pressure to the machine and raise the upper head assembly to its full upward position.
2. Pivot the knife guard back and hold it in this position, as shown in the figure below.
3. Carefully cover the knife teeth with tape.
4. Loosen, but do not remove, the knife fastening screws [A]. Remove and discard the old knife.
5. Clean the knife mounting bracket.
6. Carefully cover the teeth on the new knife with tape.
7. Position the new knife [B] with the beveled side away from the mounting bracket.
8. Mount the knife so that the screws bottom out in the slots. This position automatically gives the proper mounting and cutting angle.
9. Tighten the screws that secure the knife.
10. Slowly pivot the knife guard back and forth to ensure proper clearance.
11. Remove the tape from the new knife.
Caution
!
Be sure the knife does not interfere with the
knife guard.
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Disassembly/Reassembly 3M-Matic 800rf Case Sealer
4-12. Knife Replacement, Lower Taping
Head
Warning!
The Tape Cut-Off Knife is very sharp. To avoid personal injury, handle the knife with special care. Also, disconnect the power before starting this procedure.
1. Remove the lower taping head from the case sealer and lay it on a flat work surface.
2. Replace the knife using the knife replacement procedure described for the upper taping head; Procedure 4-11 in this section.
4-13.
Belt Drive Pulley Assembly Ribbed Rings
1. Remove the side drive belt assembly using Procedure 4-3 in this section.
2. Remove the side drive belt using Procedure 4-4 in this section.
3. Remove the bolt and washer from the bottom of the rod. Slide the rod out of the threaded sleeve.
4. Remove the self-locking nut and the washer from the top of the wrap pulley assembly [43].
5. Remove the nut and washer from the top of the idler roller assembly [51].
6. Remove the M22 nut from the top of the threaded sleeve.
7. Remove the three (3) hex-head bolts and washers from the top of the belt drive pulley assembly [15].
8. Remove the eight (8) hex-head bolts and washers from the upper half of the side drive belt assem­bly.
9. Lift the upper half of the side drive belt assembly off of the lower half, disengaging the upper timing belt [71], and lay it aside.
10. If necessary, remove the old ribbed rings [17] from the belt drive pulley assembly [15].
11. Slide the replacement ribbed rings [17] into place, ensuring that the ribbed surface faces outward.
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12. To reassemble and reinstall the side drive belt assembly, perform steps 1 through 9 in reverse order.
13. When the side drive belt assembly has been reassembled and reinstalled, perform the follow­ing adjustment procedures described in Section 3.
Motor Drive Belts, Upper and Lower
Side Belt Tension
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Disassembly/Reassembly 3M-Matic 800rf Case Sealer
4-14. Infeed Rollers
1. Remove the photocell connectors [40] from photocells PC1 and PC2.
2. Remove the front photocell support bracket [34] secured by 3 hex-head screws.
3. Remove the Infeed front side cover [31] exposing the roller drive chain [25], roller sprockets [23], motor drive sprocket [11], and roller flanged bearings [15].
4. Remove the rear photocell reflector support bracket [34] secured by 3 hex-head screws.
5. Remove the Infeed rear side cover [31] exposing the roller drive chain [25], roller sprockets [23], motor drive sprocket [11], and roller flanged bearings [15].
6. Loosen, but do not remove, the four (4) motor positioning hex-head bolts.
7. Move the motor [26] upward providing slack in the chain [25].
8. Tighten the motor bolts to hold the motor in this position.
9. Remove the chain slide [13].
10. If the chain has enough slack, slip it over the motor drive sprocket [11]. If the chain does not have enough slack, locate and remove the master chain link and remove the chain.
11. Identify the roller you are replacing and remove the roller sprocket [23] secured by a hex screw at the keyway.
12. Remove the front and rear roller flanged bearings [15] secured by three (3) hex-head screws each.
13. Loosen the roller spacer collars located on the roller shafts at each end of the roller. Each collar is secured by (2) set screws. Loosen the set screws until the collars turn freely.
14. Slide the roller shaft to the left through the hole created by the bearing removal. Then, lift the right side of the roller up and out of the Infeed frame.
15. Install the new roller by following the reverse order of the disassembly procedure.
ü Note
Be sure to align the drive chain. Install the chain taunt around all roller and drive sprockets. Do this by loosening the four (4) motor bolts, moving the motor downward until the chain is taunt with no slack, and then tightening the bolts. Also, be careful when inserting the photocell electrical connectors. Notice that the 4-pin connectors are keyed for proper pin positioning.
4-12 3M 1998 December
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3M-Matic 800rf Case Sealer Disassembly/Reassembly
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Disassembly/Reassembly 3M-Matic 800rf Case Sealer
4-15. Overload Circuit Breaker
1. Pull and hold down on the silver release clip located at the bottom and rear of the circuit breaker. Refer to the figure below.
2. Pull outward on the bottom of the circuit breaker and lift up and away from the DIN rail.
4-14 3M 1998 December
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3M-Matic 800rf Case Sealer Theory of Operation
Table of Contents
5. Theory of Operation ..................................................................................................................................... 5-1
5-1. General .............................................................................................................................................. 5-1
5-2. Operation Summary ...........................................................................................................................5-1
5-2-1. Random Mode....................................................................................................................... 5-1
5-2-2. Fixed Mode ...........................................................................................................................5-2
5-2-3. Bypass Mode......................................................................................................................... 5-2
5-3. Sequence Tables .................................................................................................................................5-2
5-4. Electrical System ............................................................................................................................. 5-14
5-4-1. Power Distribution .............................................................................................................. 5-14
5-4-2. Special Circuits/Components.............................................................................................. 5-14
5-4-3. Electrical Schematic ........................................................................................................... 5-16
5-5. Pneumatic System ............................................................................................................................ 5-20
Pneumatic Diagram............................................................................................................. 5-21
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Theory of Operation 3M-Matic 800rf Case Sealer
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3M-Matic 800rf Case Sealer Theory of Operation
5. Theory of Operation
5-1. General
This section begins with an operation summary, which gives an overview of the operations that the Model 800rf Type 39800 Case Sealer performs as it seals a carton. Next, the sequence tables provide a detailed sequence of actions the case sealer performs while operating in Random mode, Fixed mode, or Bypass mode. Then, the electrical system is de­scribed, including special circuits and components. The section ends with a description of the pneumatic system.
5-2. Operation Summary
The 800rf case sealer runs in three separate modes of operation: Random, Fixed, and Bypass. These operating modes are described in the following subsections.
5-2-1. Random Mode
When a box enters and passes through the case sealer, it passes six photocells in sequence. As the box clears the light path of the first photocell, the infeed gate moves up to prevent the entry of the next box. A pair of centering rails then move inward to center the box on the infeed rollers.
Infeed drive rollers move the box past a second photocell which senses the presence of the box to subsequently control the timing of the side belt restart circuit.
The box continues to move, blocking the light path of the third photocell. This causes the side belt drive assemblies to move inward and press against the sides of the box. The counter adds 1 to the cycle count, and the box is carried forward, blocking the light path of the fourth photocell. The side belt drive motors turn off, and the box stops at the fork beneath the head assembly.
When the box blocks the light path of the fourth photocell, the side belt drive assemblies lock in position, the upper head assembly brakes unlock, and the head assembly begins to move downward. This downward movement continues until a paddle presses against the front flap of the box, folding the flap inward. Downward movement of the head assembly continues until resistance of the box leading edge moves the paddle upward, actuating the box height limit switch. An output from the controller stops downward movement of the head assembly. At this time, the head assembly and paddle lock in position, the fork moves down, and the rear flap-folding process occurs.
Rear flap folding begins with the action of the flap folder arm. As this arm moves downward, an associ­ated limit switch actuates an output from the control­ler which causes the rear flap folder to move down, folding the rear flap of the box inward.
The timing for the side belt drive motors to start depends on whether the box is short or long. For a short box (second photocell not blocked), the drive motors are delayed momentarily to allow the rear flap to be folded and then the motors turn on. For a long box (second photocell blocked), the side belt drive motors turn on first and then the rear flap is folded when the box clears the second photocell.
The side belt drive assemblies move the box toward the taping heads. As the box moves forward, the side flaps are folded inward and then held in position by compression rollers. The box passes between the taping heads and a C-clip of tape is applied to the top and bottom center seams of the box.
As the box exits the case sealer, it clears the light path of the fifth photocell and the controller homes the case sealer, preparing it for the next box. At this time, the flap folder arm and rear flap folder move up, the side belt drive assemblies move out, the paddle moves down, and the upper head assembly raises and locks in the up position.
Copyright 1999, 3M IPC. All rights reserved. 5-1
Page 100
Theory of Operation 3M-Matic 800rf Case Sealer
During normal operation, as the box exits the case sealer it blocks the light path of the sixth photocell momentarily. When the box clears this light path, the controller allows the next box to enter the machine.
If cartons accumulate on the customers exit con­veyor, a box may be blocked and unable to exit the case sealer, or a box may be pushed back into the machine. In either case, the light path of the sixth photocell is blocked. If it remains blocked for more than a few seconds, the infeed gate stays up and the rollers stop, preventing more boxes from being fed into the case sealer until the blockage is removed.
5-2-2. Fixed Mode
Use Fixed mode to run boxes through the machine that are all the same height. The upper head assembly stays down and is locked in the position determined by the first box run through the machine in Fixed mode.
The Fixed mode flap folding and box taping pro­cesses operate the same as in Random mode. How­ever, the side belt drive assemblies move out at the beginning of the cycle rather than at the end of the cycle. This allows the infeed gate to move down and admit the next box before the previous box has left the side belt drive assemblies.
The time saved by entering the next box early and by not raising and lowering the upper head assembly speed up the throughput of the machine.
5-2-3. Bypass Mode
Use Bypass mode to run boxes through the machine without folding the upper flaps or taping them; however, the bottom of the box will be taped. The upper head assembly remains fully raised. In Bypass mode, the infeed gate and side belt drive assemblies operate the same as in Random mode.
5-3. Sequence Tables
The sequence tables list specific events, and give the order in which the events occur as a box passes through the machine. Table 5-1 is the sequence table for Random mode, Table 5-2 is for Fixed mode, and Table 5-3 is for Bypass mode.
The table column headings are described below:
SEQUENCE
This column lists the initial operating conditions, the events that occur when the RESET button is pressed, the condition that initiates each program step, and the events that occur during each program step.
PLC
This column shows whether the Programmable Logic Controller (PLC) output is latched (PLC output ON) or unlatched (PLC output OFF). An X in this column means the PLC output is ON only for the current step.
VA LV E
This column shows the solenoid valve associated with an event. Solenoid valves are either actuated (PLC output ON) or deactuated (PLC output OFF). Refer to the 800rf Pneumatic Diagram in Section 5­5, Pneumatic System.
ACTION
This column shows the action associated with an event. For example, an assembly moving in or out.
OUTPUT
This column shows the PLC output associated with an event. PLC outputs shown in bold font are ON (+24 VDC); PLC outputs with a minus sign and regular font are OFF (0 VDC). Refer to the 800rf Electrical Schematic in Section 5-4, Electrical System.
INPUT
This column shows the PLC input associated with an event. PLC inputs shown in bold font are ON (+24 VDC); PLC inputs with a minus sign and regular font are OFF (0 VDC). Refer to the 800rf Electrical Schematic in Section 5-4, Electrical System.
5-2 Copyright 1999, 3M IPC. All rights reserved.
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